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Friction Stir Welding

Dynacast ensures leak-proof, high-strength welding that redefines reliability in manufacturing.

Benefits

Key Features

Compatible Materials

Why Choose

Friction Stir Welding?Friction Stir Welding is the smart choice for projects that demand:

Superior mechanical performance
Minimizes thermal distortion
Eliminates defects (porosity, hot cracking, shrinkage)
Welding of difficult alloys
Welding of dissimilar metals
100% leakproof parts
Precision assemblies
Lightweight parts
Highly durable parts
Highly repeatable
Environmentally friendly
Cost savings

What Is Friction Stir Welding?

Friction stir welding (FSW) is a solid-state manufacturing technology that joins metals without melting, ensuring superior strength and integrity in every weld. By eliminating common defects like porosity, cracking, and distortion, FSW delivers fully leak-proof, high-performance components that meet the demanding requirements of modern applications. Its precision and consistency make it a trusted solution for manufacturers seeking reliability, durability, and efficiency at scale.See Additional Capabilities

High-speed friction stir welding machine

Inside the Friction Stir Welding Process

Friction stir welding joins metals without melting by using a rotating tool to soften and mix the material, forming a defect-free, high-strength bond. This precise method minimizes distortion and produces welds that meet or exceed the performance of the base material.

Versatile Material Solutions

FWS enables the joining of advanced alloys once considered unweldable, including high-silicon aluminum, magnesium, and dissimilar metals. This flexibility supports lightweight designs and multi-material assemblies for breakthrough applications. The process combines materials much like “stirring dough,” ensuring a seamless metallurgical bond.

Close up of friction stir welding machine

Repeatability You Can Rely On

FSW delivers unmatched consistency in high-volume production. With rigid clamping, precise tooling, and seamless CNC integration, Dynacast achieves welds that are repeatable, reliable, and defect-free every time.

Leak-Test Performance Every Time

Unlike traditional fusion welding, FSW eliminates porosity and hot cracking, ensuring 100% leak-proof joints. This makes it ideal for battery trays, cooling plates, and enclosures where fluid-tightness is critical. The process offers long-term durability with superior mechanical and sealing performance.

Dynacast employee in manufacturing facility

A Sustainable Manufacturing Choice

FSW eliminates the need for filler materials, shielding glass, and harmful emissions, reducing environmental impact. By lowering energy use and material waste, the process aligns with global sustainability goals. It’s a cleaner, greener solution without compromising strength and reliability.

Flow chart of friction stir welding process

Convert to FSW and Transform Production

By replacing secondary processes like manual assembly, tapping, or brazing, FSW streamlines manufacturing and cuts costs. Companies that adopt FSW benefit from faster cycle times, lower labor needs, and stronger, more durable assemblies.

A Look At
Friction Stir Welding Applications

Friction stir welding applies an advanced process to manufacture a wide variety of high-quality components. Common applications include:

Cold plates for CPUs, GPUs, and data center cooling systems

Battery trays (floor and frame)
Battery casings
Battery cooling packs
PACK tray water cooling
Drive motor housings
Housings for electrical control systems
Heatsinks
Bearing shields
Resolvers
Rotors
Stators/stator carriers
Transmission housings
Centre housings
Power inverters
Flange builders
Vacuum chambers
Stiffened panels
Decks for fast ferries
Floor and lateral structures
Hydrogen cryogenic tanks
Space launcher components
Panels

BEYOND THE BASICS

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