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Friction Stir Welding
Definition
Friction Stir Welding (FSW) is a solid-state metal joining process producing high-strength, defect-free joints in metallic materials. The process employs a pin tool with a low rotational speed and applied pressure that "mechanically stirs" two parent materials together to produce a uniform weld. NCAM has three machines for FSW called the Universal Weld Systems or UWS 1-3, in the order in which they were installed.
Universal Weld System #2 (UWS2)
Machine Type
- MTS 6 axis of motion weld head
Capacity
- 40 ft. 10 in. X-Axis x 22 ft. 8 in. Y-Axis x 12 ft. 2 in. Z-Axis of linear motion
- 2 axis of gimbal motion of the weld head
- 22 ft. rotary table with one rotational degree of freedom
- 40 ft. x 20 ft. flat weld area with T-slots
Features
- Capable of fixed pin / retractable pin / self reacting Friction Stir Welds
- Combined axis of motion allows for complex curvature
welding
- Latest controlled/programming system
- One of the largest, most advanced FSW machines in the world
Recent Application
Lockheed Martin built a NASA Orion crew module Ground Test Article (GTA) at Michoud using the NCAM UWS2 for friction stir welding. The vehicle will serve as a production pathfinder to validate the flight vehicle production processes and tools.
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| Lockheed Martin workers calibrate the machine prior to welding on the GTA. Image Credit: NASA. |
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Workers prepare to do welding on the crew module aft dome ring of the GTA. Image Credit: NASA. |
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