Friction Stir Welding (FSW) Tool

FSW ferrous and nonferrous alloys require a tool that can withstand temperatures of  900–1,000 degC at high x- and z-axis loads, produce consistent weld properties, and maintain high abrasion-resistance. The Megastir FSW tool consists of a polycrystalline cubic boron nitride (PCBN) tip, a locking collar, and a tungsten carbide shank.

PCBN tip

Used for its thermal stability, hardness, and strength at elevated temperatures, PCBN is classified as a superabrasive material and is suitable for ultraHPHT processes.

Locking collar

The locking collar is made from a superalloy and transmits the torque from the shank to the tip during FSW. A blind hole on the collar is used for positioning a Type K thermocouple. As the FSW tool is inserted into the liquid-cooled tool holder, a thermocouple wire slides into the collar. A set screw holds the thermocouple firmly against the side of the PCBN tip, enabling consistent temperature readings while the tool is rotating.

Tungsten carbide shank

Tungsten carbide has relatively high thermal conductivity and rigidity. During FSW, a liquid-cooled tool holder manages the removal of heat from the shank.

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Friction Stir Welding (FSW) Tool

Friction stir welding tool
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