Friction stir welding tool ｜ NTK Ceramics
Friction Stir Welding (FSW) is a solid-phase welding technique developed in the UK in 1991. It uses a rotating cylindrical tool with a protruding tip to generate frictional heat, softening the material and enabling plastic flow for strong, deformation-resistant joints.
Unlike fusion welding, FSW does not melt the materials, reducing deformation, improving grain refinement, and maintaining joint strength. Additionally, it is more energy-efficient than traditional welding methods.
While welding technologies for aluminum alloys are advancing in vehicle manufacturing, iron/steel materials pose challenges due to their high softening temperatures and the limited availability of cost-effective, high-temperature-resistant tools.
NTK CUTTING TOOLS is driving progress in Friction Stir Welding (FSW) for these materials by utilizing its expertise in ceramic materials and advanced technologies.
| Tool life | Tool cost | |
|---|---|---|
| NTK Ceramics | ○ | ◎ |
| PcBN type | ◎ | × |
| Carbides | Processing not possible (tool melting) | |
| HSS | Processing not possible (tool melting) | |
*Ferrous metals: steel, stainless steel, copper
| Line Welding conditions guideline | Rotation speed(min-1) | 1000 – 2000 |
| Welding speed (mm/min) (SFM) | 1000 – 2000 3.3 – 6.6 |
| Tool Materials | High Strength SiAlON Ceramics |
| Fine particle cemented carbide | |
| Shank dia. | ⌀ 8, 10, 12, 16, 20mm .320, .400, .472, .630, 787inches*Availability larger than ⌀ 20 mm .787” is available, |
Previously, SUS was sprayed onto steel to improve surface performance. Can be easily joined by FSW
| High-tensile steel | ||
|---|---|---|
| Welding method | Line welding | |
| Welding material | Material | SPFC980 ( High-tensile980MPa ) |
| Thickness (mm) (inch) | 1.2 .047 | |
| Tool shape | Shank Dia. (mm) (inch) | φ 6 .236 |
| Shoulder Dia. (mm) (inch) | φ 6 .236 | |
| Probe Dia. (mm) (inch) | φ 3 .120 | |
| Probe length (mm) (inch) | 0.9 .035 | |
| Welding conditions | Rotation speed (min-1) | 1000 |
| Welding speed (mm/min) (SFM) | 100 .328 | |
| Welding distance (mm) (inch) | 850 33.5 | |
| Thick steel plate | ||
|---|---|---|
| Welding method | Line welding | |
| Welding material | Material | Low carbon steel |
| Thickness (mm) (inch) | 15 .60 | |
| Tool shape | Shank Dia. (mm) (inch) | φ 37.5 1.48 |
| Shoulder Dia. (mm) (inch) | φ 37.5 1.48 | |
| Probe Dia. (mm) (inch) | φ 18.5 .728 | |
| Probe length (mm) (inch) | 14.7 .579 | |
| Welding conditions | Rotation speed (min-1) | 200 |
| Welding speed (mm/min) (SFM) | 50 .164 | |
| Welding distance (mm) (inch) | 500 19.7 | |
Before Welding
Conventional method – Welding
FSW (friction stir welding)
Joining without melting the base material, with minimal post-Welding deformation.
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