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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 #3 (UWS3)
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| Image above: UWS3 in August 2010 during installation. Visible are the two blue towers and the three floor-level turntables represented in the artist's rendering below. |
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Machine Type
- MTS Robotic Weld Tool (RWT)
- 6-axis integrated weld system
Capacity
- 2 axis of gimbal motion of the weld head; pitch: +5° to -95°, roll: ±15°
- Three 20 ft. annular ring rotary tables, each with one rotational degree of freedom
- 20 ft. outer diameter, 15 ft. inner diameter annular turntables with unlimited rotary motion and locking capability
- Two columns, each with an independently operated weld head
- 7 degrees-of-freedom (DOF) delivered through 5 physical axes
- Work envelopes shown in table below:
| X-axis |
Y-axis |
Z-axis |
93 ft.
Each weld machine |
22 ft. 5 in.
Each weld machine |
12 ft.
Each weld machine |
| Note: UWS3 has 2 weld machines that share a common X-rail. Each weld head can access any of the 3 turntables. |
Features
- Capable of fixed pin / retractable pin / self reacting Friction Stir Welds
- Combined axis of motion allows for complex curvature welding
- Control system provides coordinated motion for all 7 axes of the UWS3
- One of the largest, most advanced FSW machines in the world
- Floor level turntables
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