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12 09, 2019

What is Friction Stir Welding?

2019-09-12T18:36:18+00:00September 12th, 2019|

This image depicts a friction stir-welding machine joining two large, cylindrical aerospace vehicle components.

What is friction stir welding?

As the name suggests, “friction stir welding” (FSW) is a metal joining technique that uses friction heat to unite metal structures. In traditional welding, high levels of heat are applied thereby melting two metal parts into one another. By contrast, FSW is a solid-state joining technique that takes advantage of metal atom’s cohesive forces that cause them to diffuse into each other. The friction generates temperatures below the melting point, but high enough where the plasticized material can move around.

How does friction stir welding work?

The key in FSW is the non-consumable rotating tool. The tool, that looks similar to a drill bit, is made up of two components: a probe, a small cylinder which will penetrate into the width of the metals at their joint; and a shoulder, a larger cylinder which will spin along the surface of the metal pieces. The rotating tool supplies both the heat and the pressure needed for the weld.

The metal pieces are clamped tightly in a butt or lap joint configuration, and the mechanical rotating tool is programmed to run along the joint. The spinning tool inserted between the tightly clamped metal creates enough friction heat for the atoms of the two metals to move around. The plasticized metal moves around the probe and then fills the cavity behind the tool before coalescing into a single piece of metal.

Close up image of the drill bit-like rotating tool on a friction-stir welding machine.

What are the advantages of friction stir welding’s solid state joining for aerospace, shipbuilding, rail, aerospace, automotive industries?

There are various advantages to using FSW for metal joining:

  1. Flexibility: FSW allows efficient welding for difficult projects. FSW can be used on high-strength aluminum that can be difficult to join using conventional welding. Companies such as Taber use FSW to create aluminum extrusions in a wide array of profiles and sizes ranging from micro extrusions to 65-foot long extrusions.
  2. High strength welds: Traditional welding can introduce corruption into metals during the welding process, as it can manifest solidification cracks and porosity problems. Solid-state joining creates joints that are as strong as the metal from which they are created and are a good choice for high-strength aluminum.
  3. High quality welds: Characteristics of FSW welded metal include low distortion, reduced weight (no filler material), and excellent bonding properties.
  4. Green welding: Traditional welding consumes electrodes, energy, shielding gas, and produces noxious fumes. FSW with its non-consumable rotation tool eliminates waste.

Limitations of friction stir welding for metal joining:

The FSW spin tool must resist heat and corrosion as it moves the metal around it. Therefore, FSW best works with malleable materials with low welding temperatures.

Four, large cross-sectional profiles of aluminum parts with different patterns, shapes, and widths, and underneath an aluminum tablet with micro-aluminum profiles.

Therefore, aluminum continues to be one of the most important metals used in FSW. Aerospace, shipbuilding, rail, aerospace, automotive industries all look to aluminum FSW for high-precision aluminum extrusions and aluminum welds of high strength and quality. Aluminum FSW is particularly important because high-strength aluminum can be difficult to join using traditional methods and FSW precision allows almost infinite variety in shape and size in aluminum extrusions.

More on Taber Extrusions 

Founded in 1973, Taber Extrusions originally pioneered a process for extruding rectangular billets which enables the company to extrude solid profiles up to 31 inches wide or hollows up to 29 inches. Taber expanded with the purchase of an extrusion facility in Gulfport, MS in 1995 which houses a cast house and two additional presses, with a fabrication area that has been expanded multiple times. Besides their recently expanded capabilities to include micro-extrusions and 7” billet molds, Taber Extrusions is proud to announce friction stir-welding technology. The addition of in-house FSW capabilities creates a vertically integrated supplier of FSW panels and assemblies never before seen in North America.

Connect: Call Us Today! (888) 984-5279

12 09, 2019

Are you as proficient with this crossword puzzle as Taber Extrusions is with their services?

2020-04-03T21:25:32+00:00September 12th, 2019|

Crossword puzzle about Taber Extrusions services

About Taber Extrusions

Taber is AS9100, NADCAP, and ABS certified. Founded in 1973, Taber Extrusions originally pioneered a process for extruding rectangular billet which enables the company to extrude solid profiles up to 31 inches wide or hollows up to 29 inches. Taber expanded with the purchase of an extrusion facility in Gulfport, MS, in 1995 which houses a cast house and two additional presses, and multiple expansions of value added fabrication services.

Taber continues to extrude billet in a wide range of alloys and sizes, including 7″ billet molds, and has diversified its markets beyond military since its inception to include aerospace, automotive, marine, infrastructure, and sporting goods, among many others. For these markets, the company supplies extruded products in a variety of soft and hard alloys. In 2018, Taber added ultra-precision extrusions to their capabilities allowing them to further serve customers in electronics, computer, and medical industries. Today, Taber is proud to announce yet another exciting launch into Friction Stir Welding.

10 09, 2019

Taber Presents Friction Stir Welding Capabilities at Aluminum USA 2019

2019-09-12T18:34:22+00:00September 10th, 2019|

Stunning evening view of the Nashville city skyline along the water featuring a colorful reflection of the bright downtown lights reflecting off the water giving the entire scene a magical glow.

Aluminum industry professionals are gearing up for The Aluminum USA Tradeshow on September 12th-13th in Nashville, Tennessee, where Taber Extrusions will be showcasing their in-house friction stir welding capabilities creating a vertically integrated supplier of FSW panels and assemblies never before seen in North America.

Aluminum USA is hosted biannually as a “weeklong leading industry event covering the entire value chain from upstream (mining, smelting) via midstream (casting, rolling, extrusions) to downstream (finishing, fabrication). ALUMINUM USA is the ideal event for end-users from application industries such as automotive, aerospace, construction, packaging and electrical & electronics”. Special events surrounding the tradeshow kick off with Nissan tours on Wednesday, September 11th, and continue with an array of face-to-face opportunities including technology-based networking events and an industry meet & greet. This year’s tradeshow is bigger and better than ever, featuring an expanded show-floor.

Jason Weber who currently serves as Taber Extrusion’s VP of Marketing and Sales, will be hosting a presentation at EDU ’19, which is part of the broader Aluminum USA tradeshow on September 12th and 13th  that “gives a forum to leading suppliers and industry professionals to come together for face-to-face meetings, exhibition, cutting-edge conference, and educational programming.” Aluminum USA EDU ’19  features educational presentations covering aluminum extrusion design, applications, and technology. In addition to speaking at the EDU ’19 forum, guests are welcome to visit Jason Weber and other Taber Extrusions team members at Booth #546 during the tradeshow.

A headshot of an attractive smiling Caucasian man with slightly silvering hair, wearing an ocean blue polo shirt and a white, zip-up sweater.

Jason Weber’s presentation titled, “Joining Aluminum Extrusions through Friction Stir Welding” will present industry experts and end-users with information on Friction Stir Welding (FSW). The presentation will cover the “basics of what FSW is, current products that are Friction Stir Welded, general design practices for extrusions incorporating FSW features, and typical performance of FSW joints versus other joining technologies”.

Sometimes described as more of a forging process than actual welding – Friction Stir Welding is a solid- state joining technique used to join metals not easily fused with traditional welding. Ideal for metals such as aluminum, copper, and other metal alloys, FSW is commonly used in the aerospace, rail, automotive, shipbuilding, transportation, and marine industries. Friction Stir Welding makes possible very high-quality welds with minimal distortion. It is also a process that can be easily automated, making it an ideal solution for industrial use.

The EDU ’19 forum gives a chance for Weber to share inside knowledge of the process which the company now offers in its extensive menu of services. “As a leader in the Aluminum Industry, Taber works with clients in military, government, aircraft and aerospace, shipbuilding, infrastructure – and so much more. The aluminum extrusion shapes they are creating for these clients are absolutely ideal for Friction Stir Welding technology,” said Dave Hofferbert, President of Bond Technologies, Inc.

A close-up of a futuristic looking, metal spinning tool inserted between the metal ends of two large cylindrical spaceship parts.

Jason Weber, Vice President of Sales & Marketing for Taber Extrusions, has 20+ years of global manufacturing experience helping innovate product and service offerings. Jason is an active member of the Aluminum Extruders Council (AEC) and is the leader of the Council’s Marketing/Industry Promotion Team.

About Taber: 

Founded in 1973, Taber has become a leading supplier of high quality aluminum extrusions. By ensuring that every process and procedure, from billet procurement and final shipment, fulfills all ISO9001 and AS9100 standards, Taber maintains preferred supplier ratings. In 2018, Taber added ultra-precision extrusions to their capabilities allowing them to further serve customers in electronics, computer, and medical industries. In 2019, Taber announced their launch into Friction Stir Welding.

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