Zhihui provides engineering-driven friction stir welding services covering application evaluation, process development, prototype validation, and production manufacturing.

We also support fixture and tooling design, process optimization, quality validation, and customized FSW equipment for customers who plan to establish in-house production.

Our primary expertise is friction stir welding of aluminum alloys, including commonly used 5xxx, 6xxx, and selected 7xxx series alloys.

We also have practical experience in copper–aluminum dissimilar-metal joining. Material feasibility and process parameters are evaluated according to the specific alloy, thickness, joint design, and application requirements.

Our FSW experience covers aluminum components such as EV battery trays, motor housings, liquid cooling plates, structural aluminum components, and copper–aluminum components.

We can also evaluate other aluminum components based on part geometry, material, weld path, thickness, sealing requirements, and production volume.

Yes. We can support process development and prototype validation before volume production.

For new applications, we typically evaluate the component design, material, joint configuration, welding requirements, and quality targets before developing the welding process and tooling solution.

For an initial evaluation, please provide the part drawing or 3D model, material grade, material thickness, weld location and length, required joint performance, expected production volume, and any dimensional or leak-tightness requirements.

Based on this information, our engineers can evaluate process feasibility and recommend an appropriate FSW solution.

Quality control depends on the component and application requirements.

Typical methods may include visual inspection, dimensional inspection, leak testing, tensile or bend testing, metallographic analysis, and non-destructive testing when required. Welding parameters and inspection requirements are defined according to the specific project.

Yes. Zhihui supports both contract friction stir welding and customized FSW equipment.

Customers can use our contract welding services for process development, prototype validation, or production manufacturing, or work with us to develop a customized FSW machine for in-house production.

The appropriate approach depends on component size, production volume, process requirements, and the customer's manufacturing strategy.

Friction stir welding is a solid-state joining process in which a rotating, non-consumable tool generates frictional heat and mechanically stirs the material along the joint line.

Because the base materials are joined without melting, FSW can reduce welding distortion and avoid many solidification-related defects associated with fusion welding.

For suitable aluminum applications, FSW offers low heat input, reduced distortion, consistent joint quality, and good mechanical performance.

The process typically requires no filler wire or shielding gas and is particularly suitable for aluminum components requiring dimensional stability, sealing performance, and repeatable production.

Key FSW parameters typically include tool rotational speed, welding speed, axial force or plunge depth, tool tilt angle, and tool geometry.

The appropriate parameter combination depends on the material grade, thickness, joint configuration, tool design, equipment capability, and required weld performance.