fsw.expert GmbH

𝐔𝐧𝐝𝐞𝐫 𝐂𝐨𝐧𝐬𝐭𝐫𝐮𝐜𝐭𝐢𝐨𝐧 Sorry folks, not too many updates lately. We are working hard on amazing projects, new technologies and also in the engine room of this company these days. Stay tuned, we will be back with some updates soon. In the meantime, enjoy a picture of Alexander in his lovely outfit working on a breakthrough technology in aluminum. #fsw #solidstate #aluminum #frictionstirwelding #advancedmanufacturing

𝐖𝐞𝐥𝐝𝐢𝐧𝐠 𝐨𝐮𝐭𝐬𝐢𝐝𝐞 𝐭𝐡𝐞 𝐛𝐨𝐱 Once we were faced with a seemingly impossible task in FSW: Welding a very deep and narrow overlap joint with no side or bottom support, while maintaining tight post-weld part tolerances of /- 0.05 mm. Obviously, a standard FSW process is not capable of doing this: Too much pressure and too much heat from the shoulder. It was time to think outside the box and come up with something new, something without a shoulder in it: 𝐒𝐡𝐨𝐮𝐥𝐝𝐞𝐫𝐥𝐞𝐬𝐬 𝐅𝐫𝐢𝐜𝐭𝐢𝐨𝐧 𝐒𝐭𝐢𝐫 𝐖𝐞𝐥𝐝𝐢𝐧𝐠 (𝐒𝐋𝐅𝐒𝐖) So we rethought Friction Stir Welding and removed the shoulder from the equation. But we still had to keep all of its inherent process functions, such as containment and compression. So we transferred them to the pin. And it worked. The resulting SLFSW tool design is comparatively small and slim, reducing the contact area and effective lever, and thus the forces and heat input during processing. SLFSW allows weld paths almost to the edge of the component, providing a complete and gap-free joint that is impossible with a standard process. In an open access publication, link below, we demonstrated force reductions of about 80-85% and power reductions of about 75-80% compared to standard FSW processes. And even more is possible. Are you sitting in a box? Want to play outside? 𝐆𝐞𝐭 𝐢𝐧 𝐭𝐨𝐮𝐜𝐡 𝐰𝐢𝐭𝐡 𝐮𝐬! ➡ Link to the publication: https://lnkd.in/eyuBSFPx ⬅   #frictionstirwelding #fsw #oee #efficiency #welding #lowforce

𝐘𝐨𝐮 𝐠𝐞𝐭 𝐛𝐞𝐭𝐭𝐞𝐫, 𝐰𝐞 𝐠𝐞𝐭 𝐛𝐞𝐭𝐭𝐞𝐫, 𝐰𝐨𝐫𝐥𝐝 𝐠𝐞𝐭𝐬 𝐛𝐞𝐭𝐭𝐞𝐫. "Making the world a better place" is obviously a team effort for all of us. And solid-state processing offers many ways for this: From reducing the impact on the environment and workers, to better recyclability of products, to completely new and more sustainable solutions. And since we at fsw.expert GmbH are well aware that we are "standing on the shoulders of giants" who have laid the foundation for our own success, we do our best to give back to our community and, yes, maybe even improve the knowledge of what can be called "competition". Today, we would like to share with you some of our latest research in 𝐬𝐨𝐥𝐢𝐝-𝐬𝐭𝐚𝐭𝐞 𝐚𝐝𝐝𝐢𝐭𝐢𝐯𝐞 𝐦𝐚𝐧𝐮𝐟𝐚𝐜𝐭𝐮𝐫𝐢𝐧𝐠, conducted in collaboration with the great people at Bond Technologies, Inc. and with support of the Universität Stuttgart. Solid-state additive manufacturing offers many advantages, such as very low energy consumption and excellent mechanical properties. But more: Inexpensive, readily available feedstock can be used, and even direct recycling of material normally considered waste, such as machining chips, becomes possible. In our work, we propose new tooling and process strategies to reduce the mechanical and thermal impact on both the substrate and the built structure, while maintaining all the benefits of solid-state processing. So: 𝐆𝐞𝐭 𝐛𝐞𝐭𝐭𝐞𝐫 𝐚𝐧𝐝 𝐭𝐡𝐞 𝐛𝐞𝐬𝐭 𝐨𝐟 𝐭𝐰𝐨 𝐰𝐨𝐫𝐥𝐝𝐬. 𝐓𝐨𝐠𝐞𝐭𝐡𝐞𝐫 𝐰𝐢𝐭𝐡 𝐮𝐬. Please find our paper here (open access) ➡ https://lnkd.in/egNd5EPf ⬅ #afed #frictionstirwelding #fsw #oee #efficiency #welding #lowforce #additivemanufacturing #additive #manufacturing #sustainability

𝐓𝐡𝐞 𝐭𝐨𝐨𝐥 𝐭𝐡𝐚𝐭 𝐦𝐚𝐤𝐞𝐬 𝐭𝐡𝐞 𝐝𝐢𝐟𝐟𝐞𝐫𝐞𝐧𝐜𝐞 fsw.expert GmbH is probably best known for its efficient high-tech #FSW processes. Be it an incredible welding speed or welding the previously impossible. At best it's both. 𝐓𝐡𝐞 𝐤𝐞𝐲 𝐟𝐚𝐜𝐭𝐨𝐫 𝐢𝐬 𝐭𝐡𝐞 𝐭𝐨𝐨𝐥: As the only interface for us to implement the whole process, the welding results are already defined exactly here. A simple but at the same time complex truth. So it is the tool that makes the difference: between welding 1 or 5 meters per minute, between welding 7 or 30 mm deep on the same machine, ... and in the end between buying three machines or just one for your production, between losing or making a lot of money. 𝐀𝐧𝐝 𝐛𝐞𝐜𝐚𝐮𝐬𝐞 𝐭𝐡𝐞𝐲 𝐦𝐚𝐤𝐞 𝐭𝐡𝐢𝐬 𝐝𝐢𝐟𝐟𝐞𝐫𝐞𝐧𝐜𝐞, you will rarely see any of our tooling concepts in public. However, from time to time we do publish some of the older concepts, which are usually still at the forefront even after 5 or 10 years. On the left you see a tool that allows butt welding of 20 mm thick copper plates at welding speeds well over 500 mm/min. On a multi-purpose FSW machine limited to just 16 kW spindle power. At a tenth of the torque typically required for such applications. Producing no burr, but excellent mechanical properties. Want to buy one FSW machine instead of three? Want to speed up a bit? 𝐆𝐞𝐭 𝐢𝐧 𝐭𝐨𝐮𝐜𝐡 𝐰𝐢𝐭𝐡 𝐮𝐬! #frictionstirwelding #fsw #oee #efficiency #welding #copper

𝐊𝐞𝐞𝐩𝐢𝐧𝐠 𝐛𝐚𝐥𝐚𝐧𝐜𝐞 Usually if you want to go fast and achieve the best results in Friction Stir Welding, you have to generate the process heat only where really needed 𝐚𝐧𝐝 𝐤𝐞𝐞𝐩 𝐢𝐭 𝐭𝐡𝐞𝐫𝐞. But as always, there are some exceptions: In one of our aerospace applications the large thin-walled structures were made from such a challenging material combination that we had to steal some heat from the process to succeed. What you see in the picture is a detail of a three-dimensional fixture that fully integrates some copper to adjust the heat balance of the joining zone (hint: it is not just what you see on the top). Want to learn more? Have a challenging application? Get in touch with us!

𝐅𝐫𝐢𝐜𝐭𝐢𝐨𝐧 𝐒𝐭𝐢𝐫 𝐌𝐚𝐠𝐢𝐜 Two Germans doing Magic? Oh no, not Siegfried & Roy! In this case Alexander and Max helped out a customer with mastering the impossible (please note that the little turrets are untouched). And this weld is not just for your entertaining: Send your suggestions how we did this to [email protected] until March 1st, 2024. The best submission (funny ones are absolutely okay!) wins a free tool for your FSW application or an hour of consultation from and on us. #frictionstirwelding #FSW #manufacturing #welding #mastersoftheimpossible

🇬🇧 / 🇩🇪 𝐓𝐨𝐠𝐞𝐭𝐡𝐞𝐫 𝐰𝐢𝐭𝐡 𝐲𝐨𝐮 𝐢𝐧𝐭𝐨 𝐚 𝐠𝐫𝐞𝐚𝐭 2024 / 𝐙𝐮𝐬𝐚𝐦𝐦𝐞𝐧 𝐢𝐧 𝐞𝐢𝐧 𝐠𝐫𝐨ß𝐚𝐫𝐭𝐢𝐠𝐞𝐬 2024 Just before this year gets already a little too old, we would love to take the chance to wish you all a wonderful 2024. For us, it is already clear that this year will be totally different. New technology, new processes, new partners, new employees. A year of transformation, growth, and exploration: Starting with 2024, we are officially broadening our offer by incorporating 𝐬𝐨𝐥𝐢𝐝-𝐬𝐭𝐚𝐭𝐞 𝐚𝐝𝐝𝐢𝐭𝐢𝐯𝐞 𝐦𝐚𝐧𝐮𝐟𝐚𝐜𝐭𝐮𝐫𝐢𝐧𝐠 (see below). Technologies we have been working on our own for years now. We have started contributing our expertise in process development and tool design to 𝐧𝐞𝐰 𝐭𝐞𝐜𝐡𝐧𝐨𝐥𝐨𝐠𝐢𝐜𝐚𝐥 𝐩𝐚𝐫𝐭𝐧𝐞𝐫𝐬𝐡𝐢𝐩𝐬. Together, we will bring the next generation of friction stir welding to the market in 2024. 𝐍𝐞𝐰 𝐩𝐫𝐨𝐝𝐮𝐜𝐭𝐢𝐨𝐧 𝐜𝐚𝐩𝐚𝐜𝐢𝐭𝐢𝐞𝐬 will turbo charge our ability to deliver prototypes and especially small series faster than ever before. And that is just the beginning, more to come. We look forward to embarking on this exciting journey together with you. 𝐓𝐡𝐚𝐧𝐤𝐬 𝐟𝐨𝐫 𝐛𝐞𝐢𝐧𝐠 𝐩𝐚𝐫𝐭 𝐨𝐟 𝐨𝐮𝐫 𝐬𝐭𝐨𝐫𝐲. 𝐇𝐚𝐩𝐩𝐲 2024!   🇩🇪 Bevor dieses Jahr dafür zu alt wird, möchten wir die Gelegenheit nutzen, um Ihnen und Euch alles Gute für 2024 zu wünschen. Für uns ist schon jetzt klar, dass dieses Jahr ganz anders sein wird. Neue Technologien, neue Fertigungsprozesse, neue Partnerschaften, neue Mitarbeiter. Ein Jahr der Veränderung, des Wachstums und neuer Wege: Ab 2024 erweitern wir unser Angebot offiziell um die 𝐚𝐝𝐝𝐢𝐭𝐢𝐯𝐞 𝐅𝐞𝐫𝐭𝐢𝐠𝐮𝐧𝐠 in fester Phase (solid-state addititve manufacturing, siehe unten). Technologien, an denen und mit denen wir selbst seit Jahren arbeiten. Wir haben begonnen, unser Know-how in den Bereichen Prozessentwicklung und Werkzeugdesign in 𝐧𝐞𝐮𝐞 𝐓𝐞𝐜𝐡𝐧𝐨𝐥𝐨𝐠𝐢𝐞-𝐏𝐚𝐫𝐭𝐧𝐞𝐫𝐬𝐜𝐡𝐚𝐟𝐭𝐞𝐧 einzubringen. Ziel ist es, 2024 die nächste Generation des Rührreibschweißens in die industrielle Anwendung zu bringen. 𝐍𝐞𝐮𝐞 𝐏𝐫𝐨𝐝𝐮𝐤𝐭𝐢𝐨𝐧𝐬𝐤𝐚𝐩𝐚𝐳𝐢𝐭ä𝐭𝐞𝐧 werden es uns ermöglichen vor allem Prototypen und Kleinserien schneller und besser als jemals zuvor zu liefern. Und das ist erst der Anfang. Wir freuen uns darauf, 2024 gemeinsam mit Euch zu gestalten. 𝐃𝐚𝐧𝐤𝐞, 𝐝𝐚𝐬𝐬 𝐢𝐡𝐫 𝐦𝐢𝐭 𝐚𝐧 𝐁𝐨𝐫𝐝 𝐬𝐞𝐢𝐝! 𝐀𝐥𝐥𝐞𝐬 𝐆𝐮𝐭𝐞 𝐟ü𝐫 𝐄𝐮𝐞𝐫 2024! #additivemanufacturing #fsw #frictionstirwelding #solidstate #manufacturing

🇩🇪 / 🇬🇧 𝐖𝐢𝐫𝐤𝐥𝐢𝐜𝐡? 𝐄𝐢𝐧 𝐏𝐚𝐫𝐭𝐢𝐤𝐞𝐥𝐛𝐞𝐬𝐜𝐡𝐥𝐞𝐮𝐧𝐢𝐠𝐞𝐫?! / 𝐖𝐞𝐥𝐝𝐢𝐧𝐠 𝐚 𝐩𝐚𝐫𝐭𝐢𝐜𝐥𝐞 𝐚𝐜𝐜𝐞𝐥𝐞𝐫𝐚𝐭𝐨𝐫 Wenn es um Rührreibschweißen und gänzlich abgefahrene Hightech-Anwendungen geht, weiß auch die Konkurrenz, dass es meistens wir sind. Nur von uns wird man dazu nichts hören. Ganz anders diesmal und deswegen freuen wir uns umso mehr, ganz offiziell ankündigen zu dürfen, dass die fsw.expert GmbH einen Beitrag zu einem der größten wissenschaftlichen Vorhaben unserer Zeit leisten wird. Das Deep Underground Neutrino Experiment (DUNE), ein multi-milliarden Projekt des U.S. Department of Energy (DOE) am Fermilab, hat kein geringeres Ziel, als die Geheimnisse unseres Universums zu enträtseln. Die von uns gelieferten Komponenten werden dafür sorgen, dass ein 2,4 Megawatt starker Protonenstrahl aus Illinois sein 1300 km entferntes Ziel in der Sanford Underground Research Facility in South Dakota auch trifft. Wir sind schon ein bisschen aufgeregt und dankbar für die Gelegenheit, einen kleinen Beitrag zur Beantwortung solch großer Fragen der Menschheit leisten zu können. Und dass wir ausnahmsweise einmal über eines der unglaublichen Projekte sprechen dürfen, die wir mit unseren Partnern so durchführen. Mehr über das Deep Underground Neutrino Experiment ist hier zu erfahren https://lnkd.in/gX5V5Qv und - so gut es geht - werden wir von schweißtechnischer Seite etwas über dieses Projekt berichten. Und natürlich: wenn Sie etwas rührreibschweißen wollen, kontaktieren Sie uns einfach direkt. Es muss auch nicht unbedingt ein Teilchenbeschleuniger sein. 🇬🇧 𝐒𝐭𝐢𝐫𝐫𝐢𝐧𝐠 𝐚 𝐥𝐢𝐭𝐭𝐥𝐞 𝐛𝐢𝐭 𝐭𝐡𝐞 𝐟𝐚𝐛𝐫𝐢𝐜 𝐨𝐟 𝐭𝐡𝐞 𝐮𝐧𝐢𝐯𝐞𝐫𝐬𝐞 We are delighted to officially announce that fsw.expert GmbH will contribute to one of the greatest science endeavours of our lifetime. The Deep Underground Neutrino Experiment (DUNE) at Fermilab has no less a target than unravelling the mysteries of the universe. The parts we deliver will ensure that a 2.4 Megawatt proton beam from Illinois will be accurately directed towards its target, which is 800 miles away, at the Sanford Underground Research Facility in South Dakota. We are more than humbled and thankful for this opportunity to contribute a little bit to answering such big questions for mankind. And that we are, for once, allowed to talk about one of the incredible projects we carry out with our partners. You can learn more about the Deep Underground Neutrino Experiment here: https://lnkd.in/gX5V5Qv , and as much as we can, we will keep you posted about this project. And of course, if you want to FS weld something, contact us today. Does not necessarily have to be a particle accelerator. picture: © Deep Underground Neutrino Experiment

🇩🇪 / 🇬🇧 𝐖𝐢𝐫𝐤𝐥𝐢𝐜𝐡? 𝐄𝐢𝐧 𝐏𝐚𝐫𝐭𝐢𝐤𝐞𝐥𝐛𝐞𝐬𝐜𝐡𝐥𝐞𝐮𝐧𝐢𝐠𝐞𝐫?! / 𝐖𝐞𝐥𝐝𝐢𝐧𝐠 𝐚 𝐩𝐚𝐫𝐭𝐢𝐜𝐥𝐞 𝐚𝐜𝐜𝐞𝐥𝐞𝐫𝐚𝐭𝐨𝐫 Wenn es um Rührreibschweißen und gänzlich abgefahrene Hightech-Anwendungen geht, weiß auch die Konkurrenz, dass es meistens wir sind. Nur von uns wird man dazu nichts hören. Ganz anders diesmal und deswegen freuen wir uns umso mehr, ganz offiziell ankündigen zu dürfen, dass die fsw.expert GmbH einen Beitrag zu einem der größten wissenschaftlichen Vorhaben unserer Zeit leisten wird. Das Deep Underground Neutrino Experiment (DUNE), ein multi-milliarden Projekt des U.S. Department of Energy (DOE) am Fermilab, hat kein geringeres Ziel, als die Geheimnisse unseres Universums zu enträtseln. Die von uns gelieferten Komponenten werden dafür sorgen, dass ein 2,4 Megawatt starker Protonenstrahl aus Illinois sein 1300 km entferntes Ziel in der Sanford Underground Research Facility in South Dakota auch trifft. Wir sind schon ein bisschen aufgeregt und dankbar für die Gelegenheit, einen kleinen Beitrag zur Beantwortung solch großer Fragen der Menschheit leisten zu können. Und dass wir ausnahmsweise einmal über eines der unglaublichen Projekte sprechen dürfen, die wir mit unseren Partnern so durchführen. Mehr über das Deep Underground Neutrino Experiment ist hier zu erfahren https://lnkd.in/gX5V5Qv und - so gut es geht - werden wir von schweißtechnischer Seite etwas über dieses Projekt berichten. Und natürlich: wenn Sie etwas rührreibschweißen wollen, kontaktieren Sie uns einfach direkt. Es muss auch nicht unbedingt ein Teilchenbeschleuniger sein. 🇬🇧 𝐒𝐭𝐢𝐫𝐫𝐢𝐧𝐠 𝐚 𝐥𝐢𝐭𝐭𝐥𝐞 𝐛𝐢𝐭 𝐭𝐡𝐞 𝐟𝐚𝐛𝐫𝐢𝐜 𝐨𝐟 𝐭𝐡𝐞 𝐮𝐧𝐢𝐯𝐞𝐫𝐬𝐞 We are delighted to officially announce that fsw.expert GmbH will contribute to one of the greatest science endeavours of our lifetime. The Deep Underground Neutrino Experiment (DUNE) at Fermilab has no less a target than unravelling the mysteries of the universe. The parts we deliver will ensure that a 2.4 Megawatt proton beam from Illinois will be accurately directed towards its target, which is 800 miles away, at the Sanford Underground Research Facility in South Dakota. We are more than humbled and thankful for this opportunity to contribute a little bit to answering such big questions for mankind. And that we are, for once, allowed to talk about one of the incredible projects we carry out with our partners. You can learn more about the Deep Underground Neutrino Experiment here: https://lnkd.in/gX5V5Qv , and as much as we can, we will keep you posted about this project. And of course, if you want to FS weld something, contact us today. Does not necessarily have to be a particle accelerator. picture: © Deep Underground Neutrino Experiment