Hybrid Friction Stir Welding System (FSW System)

Delivery of a hybrid Friction Stir Welding (FSW) system with control and sensor technology: Force and displacement control for a force-controlled welding process (constant contact pressure or depth control) to compensate for tolerances, including gap force-controlled process for FSW process variants and force-controlled feed for AFSD consumables. Temperature control involves speed adjustment within a specified speed range. Sensors record temperature (3 measurement points in spindle 1, 2 measurement points in spindle 2, 4 static channels on upper spindle unit, 4 static channels on lower spindle unit, 20 static channels freely available on the table), position, force (x, y, z for upper, u, v, w for lower spindle module, z-direction for pin axis), speed, and torque for both spindle modules. An accelerometer on the upper spindle module measures in all 3 axis directions. Further measurements include cooling capacity, flow, temperatures, flow control for shielding gas, and energy consumption of the system. 10 additional signals for process/quality-relevant data are synchronized with process time. Process monitoring optionally includes an optical camera for upper and lower tools (live monitoring and recording), an optional seam tracking system for upper and lower spindles, and an optional infrared camera for steel materials for upper and lower tools. The control (CNC) features freely programmable g-code. Additional services include delivery, employee training, a preliminary acceptance at the manufacturer (FAT) of approx. minimum 1 week with Hereon's own material, commissioning and final acceptance at Hereon, an option for remote maintenance access, CE marking, and a 2-year warranty/guarantee including technical support. Optionally, a 3-year maintenance contract including technical support is available after the warranty period.

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