Friction Stir Welding (FSW)
Friction stir welding as a key technology for future industrial joining solutions?
As part of the DMG MORI in-house exhibition (January 26 to February 6, 2026), Friction Stir Welding (FSW) was presented as a high-performance joining process directly on the machine tool. With live machining, DMG MORI gave trade visitors a vivid insight into the industrial implementation of the solid-phase welding process with tools from Hufschmied Zerspanungssysteme.
Hufschmied Zerspanungssysteme GmbH, a manufacturer of process-optimized milling tools, presented its FSW tools at the in-house exhibition and explained the process-specific requirements for tool geometry, material selection and tool life.
Live machining on a "DMC 65 FDS" made it clear how easily FSW can be integrated into modern production environments. The FSW tools developed by Hufschmied impress with their consistent quality, robust processes and low tool wear. They therefore open up the possibility of reliable series production.
The exhibited demonstrator, a structured aluminum component with integrated functional channels, also highlighted the particular strengths of the FSW process. Welding in the solid state produces high-strength, dense and low-distortion joints, which are particularly important for applications in battery, cooling and lightweight construction technology.
Ready for the series?
According to the company, the presentation demonstrated the potential of friction stir welding as a key technology for future industrial joining solutions, especially where the highest demands are placed on component quality, tightness and structural integrity. Particular attention was paid to process-stable force control, which is crucial for consistent seam quality and reproducible results. The close intermeshing of tool, process control and machine shows that Friction Stir Welding has long since outgrown its development status and is increasingly finding its way into production concepts suitable for series production.
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