FSW-R Series Robotic Friction Stir Welding Systems — Flexible, Precise & Safer Welding Automation

Industry Pain Points

Manufacturers often face:

• Difficulty ensuring consistent quality in complex welds.

• High labor risk in hazardous welding environments.

• Limited flexibility with traditional fixed FSW machines.

• Slow integration into existing production lines.

The FSW-R series directly addresses these challenges.

Product Overview

The FSW-R robotic systems redefine friction stir welding by combining high-end KUKA robotic arms with purpose-built FSW control modules. Unlike traditional gantry-based machines, the robotic platform offers unparalleled flexibility, adaptability, and precision — making it ideal for parts with irregular geometries, 3D weld seams, and applications where space or safety is a concern.

Core Technology Highlights

• Constant Displacement Control → Maintains uniform plunge depth, reducing weld defects.

• Constant Torque Control → Ensures stable stirring force, achieving strong, consistent joints.

• Weld Seam Tracking → Real-time path adjustment guarantees accuracy on complex geometries.

Result: Lower scrap rates, improved mechanical strength, and reliable repeatability.

Safer Production Environment

• Operates in high-temperature, high-pressure, or hazardous atmospheres where manual welding is unsafe.

• Robots replace human operators, minimizing safety risks.

• Designed to maintain stable quality even under demanding industrial conditions.

Flexible Integration & Smart Programming

• Seamless integration with existing automotive and aerospace production lines.

• Compatible with KUKA, ABB, and FANUC robotic ecosystems.

• Programmable multi-axis motion enables 3D welds and spot welds.

• Modular software interface reduces setup and changeover times.

Model Specifications

FSW-R06

• Robot: KUKA KR500

• Payload: 500 kg

• Welding thickness: ≤6 mm aluminum

• Reach: 2800 mm

• Speed: ≤6000 rpm

• Footprint: ~4600 × 5200 mm

• Cooling: Circulating water FSW

FSW-R10

• Robot: KUKA Titan

• Payload: 1000 kg

• Welding thickness: ≤10 mm aluminum

• Reach: 3200 mm

• Speed: ≤5000 rpm

• Footprint: ~5600 × 5200 mm

• Cooling: Circulating water FSW

FSW-RS4

• Robot: KUKA KR500

• Payload: 500 kg

• Welding thickness: ≤4 mm aluminum

• Reach: 2800 mm

• Speed: ≤3000 rpm

• Footprint: ~4600 × 5000 mm

Application: Spot welding of aircraft structural components

Key Applications

• Automotive → Battery pack enclosures, lightweight chassis, heat exchangers

• Aerospace → Aircraft fuselage panels, wing skins, structural spot welding

• Rail & Marine → Large aluminum alloy panels, safety-critical structures

• Electronics → Enclosures requiring leak-proof, distortion-free welds

Why Choose Our FSW-R Series?

• Cutting-edge robotic FSW technology with advanced control algorithms

• Reduced scrap and higher yield rates

• Enhanced workplace safety in hazardous environments

• Seamless automation and flexible production line integration

• Proven success in aerospace, EV, and industrial projects

FAQ

Q1: What advantage does robotic FSW offer over gantry-based systems?

A1: Robotic FSW offers greater flexibility in handling 3D weld paths and irregular geometries, whereas gantry machines are more suited for flat or large uniform panels.

Q2: How does weld seam tracking improve quality?

A2: Real-time tracking allows the robot to adjust its path dynamically, ensuring weld seam accuracy even when workpiece tolerances vary.

Q3: Can the FSW-R integrate into an existing automotive line?

A3: Yes, it supports plug-and-play integration with major robot brands and can connect with MES/ERP systems for smart manufacturing.

Q4: Is robotic FSW suitable for aerospace-grade aluminum?

A4: Absolutely. Its precise control and non-porous welds meet the high standards of aerospace structural parts.

Q5: What is the maximum thickness achievable?

A5: Depending on the model: RS4 (≤4 mm), R06 (≤6 mm), R10 (≤10 mm).

CTA

Looking to automatecomplex aluminum welding with precision and safety? Contact us today to discuss your FSW-R solution.