1. Feasibility & Prototyping

• Objective: Evaluate the technical feasibility of FSW for specific materials, joint designs, and part geometries.

• Activities:

  • Conduct initial trials on prototype parts to verify that FSW can meet design, mechanical, and metallurgical requirements.

  • Optimize key welding parameters such as tool rotation speed, traverse speed, and plunge depth.

  • Perform preliminary inspections including visual checks and non-destructive testing (NDT).

  • Design and evaluate appropriate clamping and fixturing solutions to ensure part stability and minimize distortion during welding.

  • Develop and test welding tools (pins and shoulders) tailored to the material and joint configuration to optimize heat generation and material flow.

• Standards Reference:

  • ISO 25239-4: Specification and qualification of FSW welding procedures for aluminum alloys.

  • ASM International guidelines on FSW process feasibility and parameter optimization.

• Outcome: Confirmation of weld feasibility and a validated initial weld process suitable for further development.

• Decision Point:
  Customers decide whether to proceed with contract manufacturing or invest in on-site FSW equipment based on feasibility results.

2. Small-Scale Production

• Objective: Refine and stabilize the welding process under controlled production volumes to ensure repeatability and process control.

• Activities:

  • Produce small batches of parts applying optimized welding parameters.

  • Implement process monitoring and control systems to maintain weld consistency.

  • Conduct detailed mechanical testing including tensile, fatigue, and corrosion resistance as applicable.

  • Finalize clamping and fixturing designs for production to ensure consistent part positioning and minimize residual stresses.

  • Optimize tool design and wear characteristics for sustained production runs, including tool material selection and cooling methods.

• Standards Reference:

  • ISO 15614-14: Specification and qualification of welding procedures for friction stir welding.

  • AWS D17.3: Specification for friction stir welding of aluminum alloys (widely used in the US aerospace industry).

• Outcome: A stable, repeatable welding process ready for formal qualification.

3. Part Qualification

• Objective: Complete formal qualification of the welding procedure and parts to meet customer and regulatory requirements.

• Activities:

  • Perform comprehensive testing and validation per applicable standards such as ISO, AWS, or customer-specific protocols.

  • Document welding procedure specifications (WPS), inspection criteria, and quality assurance plans.

  • Obtain certifications or approvals required for production release.

• Standards Reference:

  • ISO 25239 series: Covers FSW process requirements and qualification for aluminum and other alloys.

  • ASTM E165/E165M: Standard practice for liquid penetrant examination, often used in weld inspection.

• Outcome: Certified welding procedure and qualified parts ready for volume manufacturing.

4. Full-Scale Production

• Objective: Scale up to high-volume manufacturing with consistent quality, efficiency, and compliance.

• Activities:

  • Deploy dedicated FSW equipment with optimized tooling, automation, and process controls.

  • Maintain rigorous quality control, including in-process monitoring and periodic requalification.

  • Utilize OEM support for maintenance, upgrades, and continuous improvement.

  • Ensure robust clamping and fixturing systems are integrated into production lines to maintain repeatability and minimize distortion.

  • Implement tool management programs to monitor wear and schedule timely replacements, ensuring consistent weld quality.

• Standards Reference:

  • ISO 3834: Quality requirements for fusion welding of metallic materials (applicable to overall welding quality management).

  • Relevant industry-specific standards depending on application (e.g., automotive, aerospace).

• Outcome: Efficient, cost-effective, and high-quality FSW production meeting customer and regulatory demands.