29 12, 2023

Friction Stir Welding Services Spotlight: End Applications

2023-12-29T22:02:52+00:00December 29th, 2023|

A double-sided friction stir welding machine simultaneously welds two sides of the metal. Under that is the blog title: “Friction Stir Welding Services Spotlight: End Applications” and the Taber logo.

 

Friction stir welding is a solid-state process where a non-consumable tool generates heat through friction, softening the workpiece near the tool. The softened metal is mixed and forged under mechanical pressure, creating a steel-strong bond. It’s akin to a sculptor shaping and uniting metal like clay or dough.

FSW was invented in 1991 by The Welding Institute (TWI) in the United Kingdom, and it has since become one of the most versatile and widely used welding processes in the world. This blog delves into the realm of FSW, covering the process, its advantages over traditional methods, and its applications across industries.

Unlocking the Hidden Benefits of FSW — Your Ultimate Guide!

 

An infographic about the advantages of FSW and which industries benefit most from friction stir welding.

 

FSW has revolutionized the welding process and changed the way we join metals. It is a versatile and efficient process that offers several advantages over traditional welding processes.

  • High weld quality: FSW is a solid-state welding process that produces robust, flexible, tough welds without melting the metal and eliminating defects.
  • Low distortion: This localized welding technique minimizes distortion in welded components by concentrating heat near the weld area.
  • Wide range of materials: FSW can weld various materials like aluminum, magnesium, copper, and steel alloys

In addition to these advantages, FSW is a reliable and repeatable welding process. This makes it ideal for high-volume production applications.

 

A vector compilation of trains, buses, helicopters, subways, and airplanes in blue tones.

FSW Services Have Revolutionized Joining Metals (particularly in U.S. aluminum extrusions)

The industries that use the most FSW are:

Aerospace

Due to the need for aircraft fuselages to act as engine components, the aerospace sector has embraced FSW services for their lightweight, high-strength characteristics and their ability to maintain optimum structural integrity after being welded.

Automotive and rail

FSW finds its application in producing aluminum-intensive cars, where robust and reliable joints are paramount. By utilizing FSW technology, automotive manufacturers can reduce weight while maintaining structural integrity, improving performance and safety.

Marine

The marine industry widely employs FSW for welding aluminum structures that need high strength and corrosion resistance. It produces high-quality welds and is more environmentally friendly than other welding processes. Its use in the maritime industry has led to significant cost savings, improved efficiency, and better-quality welds.

Electronics

The electronics industry uses FSW to produce heat sinks and join dissimilar metals, such as copper and aluminum. It offers improved thermal performance, reduced weight, and reliable and repeatable welds, making it an attractive option for electronic device manufacturers.

General fabrication

FSW provides a solid-state welding process that results in high-quality, defect-free welds. It is also ideal for welding various materials, such as aluminum, magnesium, copper, and steel alloys, and has less distortion and fumes than traditional welding processes.

Various other sectors, such as energy, construction, and medical devices, also utilize FSW in addition to these industries. The FSW process is a great partner for demanding applications because it creates seamless and defect-free welds in large aluminum extrusions.

Taber Extrusions Expands Capabilities with Friction Stir Welding

 

Watch the “Taber: Advanced Friction Stir Welding Capabilities” video here: https://www.youtube.com/watch?v=Xw5sxgHSn7I

 

 

If your company is in need of friction stir-welding services, consider the leading American aluminum extrusion company—Taber Extrusions.

Taber’s FSW capabilities allow them to create panel assemblies that are very large (up to 200 inches wide by 65 feet long). They can also make double-walled hollow extrusions up to 6.5 inches tall, 32 inches wide, and 65 feet long. The FSW production cell carries out all of this through a unique production process, which also trims the profiles of the panels before joining them.

Taber’s in-house FSW capabilities provide its customers with a more comprehensive suite of services, meeting the ever-increasing demand for FSW across various industries.

More About Taber Extrusions: 

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 a facility in Gulfport, MS., in 1995, which houses a state-of-the-art cast house and two additional presses, micro-extrusion capabilities, and the fabrication area has been expanded multiple times – with the most recent being the addition of the new larger machining center.

Taber continues to extrude billet in a wide range of alloys and sizes, 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 cast and extruded products in a variety of soft and hard alloys.

Today, Taber Extrusions is proud of its friction stir welding capabilities, and full offering of extruded aluminum components, value-added machining services and raw material supply to the North American market.

Taber Extrusions is here to make your dreams a reality. Taber’s team of experts will guide you through the entire process, from selecting the perfect custom shape to choosing the suitable alloy. And their award-winning extrusion process will bring your project to life.

Follow Taber Extrusions:

LINKEDIN: https://www.linkedin.com/company/taberextrusions/

FACEBOOK: https://www.facebook.com/taberextrusions/

TWITTER: https://twitter.com/taberextrusions

 

Are you interested in becoming a part of the Taber team? Submit your resume to careers@taberextrusions.com.

27 10, 2023

U.S. Aluminum Extruder Study: Aluminum Extrusions in Energy

2023-10-27T16:56:53+00:00October 27th, 2023|

Creative graphic featuring images of aluminum extrusions used in solar energy with the words “Aluminum Extrusions in Energy” in blue font. Official Taber Extrusions logo and www.taberextrusions.com at the bottom.

In our past articles, we’ve delved into the many benefits of aluminum and its role in shaping and building everything around us. This generous element with its many properties has proven time and again how it became the go-to material for designers and engineers across all sectors.

Today, we’ll be looking into how aluminum — particularly the aluminum extrusion industry — plays a role in a sector that is rapidly growing and changing how we harness the power of nature around us — energy.

The dynamic and symbiotic relationship between these sectors is pivotal to our world today. It is only fitting that we at Taber, a U.S. aluminum extruder company and among the industry leaders in sustainable aluminum products, showcase how we can make the most of this relationship to effectively harness renewable energy that is readily available to us.

As Elon Musk put it, “We have this handy fusion reactor in the sky called the sun; you don’t have to do anything, it just works. It shows up every day.”

 

Aluminum Extrusion Industry + Energy Sector = Sustainable Limitless Energy

The aluminum extrusion industry presents a myriad of offerings to the energy sector, positioning itself as a cornerstone of sustainable innovation. Leveraging the unique properties of aluminum, the extrusion process enhances the metal and makes it possible to create profiles that can be used for a variety of components. These components are essential for optimizing efficiency in various applications such as wind turbines, solar panels, and transmission systems to name a few.

What does aluminum extrusion offer compared to other metals?

  • Versatility in shape and design ✅
  • Durability and resistance to corrosion ✅
  • High thermal conductivity ✅
  • Reflective surface ✅
  • High strength-to-weight ratio ✅
  • Cost efficiency and decreased maintenance ✅
  • Unlimited recyclability ✅

 

Solar Energy 

The most common and widely used form of solar energy today is photovoltaic solar panels or PV systems that harness radiant light from the sun and convert it to electricity. They are utilized for both small and large-scale applications providing electricity that power small electronic devices to large sun farms that can provide power to entire cities.

From the left of a four-panel frame is a silhouette of three towering wind turbines with a coastal sunset, solar panels facing upward under a mostly clear blue sunny sky, a glass facade of a modern building reflecting tall green trees, and a rustic hydropower dam with water raging down onto a body of water with rocks on the shore.

Aluminum extruded components are widely used in PV systems because of their rich properties. In a 2020 study by the World Bank, PV systems use 85% aluminum for their systems. Taber Extrusions offers a wide range of profiles and extrusion capabilities for your solar energy components:

Solar panel frames

The lightweight nature of aluminum ensures that the frames do not add unnecessary weight to the PV system. Additionally, the resistance to corrosion properties of aluminum enables the frames to withstand exposure to various weather conditions.

Mounting systems (racking and trackers)

Mounting systems, which secure solar panels to rooftops, ground installations, or other structures, use aluminum extrusions. One reason they are used is because of strong and adaptable frameworks that can be customized to fit different installation scenarios.

Heat sinks and dissipators

Solar panels can generate heat during operation, which can impact their efficiency. Aluminum’s high thermal conductivity makes it an excellent choice for creating heat sinks and dissipators, that help regulate the temperature of the solar panels and maintain their optimal performance.

Enclosures and junction boxes

Extruded aluminum is used to create enclosures and junction boxes that house electrical components within the PV system. They protect electrical and mechanical components from environmental factors and allow efficient heat dissipation.

Wind Energy

Wind turbines or mills predominantly use other materials such as steel, copper, plastic, and wood. According to the USGS, wind energy uses about 2% aluminum in its production. However, in recent years, aluminum is catching on because of the properties that make it easy to work with and its proven economic benefits.

It outperforms all other metals in terms of corrosion resistance, making it exceptionally well-suited for maritime environments. It is particularly advantageous for offshore wind turbines, where the onslaught of waves, humidity, salty sea air, and storms can accelerate corrosion.

According to an article by alcirclebiz.com, while copper typically reigns supreme as the wiring material of choice, experts in the field of wind turbines are now exploring an alternative: aluminum. Aluminum wiring cost less compared to copper helping reduce project costs. It also weighs approximately 70% less than copper, rendering electrical cables crafted from aluminum not only lightweight but also easier to install.

Hydropower Energy

A hydropower plant generates energy using the motion of water. The water is directed through a pipe, known as a penstock, where it exerts pressure on turbine blades. In turn, these blades are set into motion, causing the turbine to rotate and drive a generator, ultimately producing electricity. Because water causes corrosion to some metals, aluminum alloys are used to reduce cost and corrosion in components.

Here’s how aluminum and aluminum extrusion can be utilized in hydropower energy:

  • Penstock structures
  • Gates and valves
  • Turbine components
  • Intake structures
  • Cooling and ventilation systems
  • Control panels and electrical enclosures
  • Support structures for hydro facilities

Green Buildings and Infrastructure

A graphic illustration of green city life inside an outline of a lightbulb with an outlet. On the top right are two green butterflies flying away.

In the construction industry, the lightweight yet strong, malleable, and recyclable nature of extruded aluminum aligns perfectly with the principles of eco-friendly design. Consequently, green buildings and structures are highly incentivized by governments around the world and have been gaining popularity in recent years.

Here’s how aluminum extrusion brings elegance and sustainability to modern architecture:

  • Energy-efficient windows and doors
  • Solar panel mounting systems
  • Facade and curtain wall systems
  • Structural components
  • HVAC systems and ductwork
  • Interior design elements
  • Efficient lighting systems
  • Water management and rainwater harvesting
  • Accessible ramps and railings

Beyond their environmental benefits, alternative energy sources also present significant economic opportunities. As nations transition to cleaner energy, they unlock new avenues for job creation, technological innovation, and sustainable economic growth. Alternative energy sources reduce reliance on imported fossil fuels, enhancing energy security and minimizing vulnerability to price fluctuations and geopolitical tensions.

A circle of hands and feet from a group of people on luscious green grass with the white version of the Taber Extrusions logo floating in the middle.

U.S. Aluminum Extrusions Industry Working Together on Sustainability

The U.S. aluminum extrusion industry, and leading extruders like Taber Extrusions, are dedicated to pushing boundaries in terms of innovation. They are setting the stage for responsible energy solutions. Their commitment to sustainability isn’t just inspiring; it’s groundbreaking.

It’s about building and designing a world where energy efficiency and environmental responsibility meet advanced research and technology. This partnership isn’t just about structures; it’s about reshaping our future.

The path to sustainability is paved with aluminum extrusion, with Taber Extrusions leading the way.

More About Taber Extrusions

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 new state-of-the-art cast house and two additional presses, has micro-extrusion capabilities, and a fabrication area that has been expanded multiple times.

Taber continues to extrude billet in a wide range of alloys and sizes and has diversified its markets beyond the military since its inception to include aerospace, automotive, marine, infrastructure, and sporting goods, among many others. For these markets, the company supplies cast and extruded products in a variety of soft and hard alloys.

Today, Taber Extrusions has completed the addition of in-house friction stir welding capabilities and carries on their offering of extruded aluminum components, value-added machining services, and raw material supply to the North American market – making them a vertically integrated supplier of FSW panels and assemblies never seen in North America.

Follow us on Social Media:

LINKEDIN:  https://www.linkedin.com/company/8843183/

FACEBOOK:  https://www.facebook.com/taberextrusions/

TWITTER:  https://twitter.com/taberextrusions

YOUTUBE:  https://www.youtube.com/@TaberExtrusions

Interested in becoming a part of the Taber Team?  Submit your resume to careers@taberextrusions.com. Visit us: www.taberextrusions.com or call us at (888) 985-5319.

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