FSW tools for Aluminium-Silicon welding

The challenge :

Aluminium silicon alloys contain silicon particles, which are very abrasive for tools  and more particularly for the pin.

This leads to very fast wear after a few tens of weld meters.

Light casted alloys are used in context where mass saving are sought, such as automotive sector. This process is used for the manufacturing of engine blocks, heat exchangers, battery casings and wheels. 

Case study : aluminium casting

-Cheaper (welding remplaces screwing)
-More resistant
-Lighter
-More complex designs, impossible by casting
-Perfectly sealed
-Perfect thermal conductivity (metallurgical bonding)

The replacement of screwing by FSW welding is democratized in the automotive sector.