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Friction Stir Welding Applications

FSW Applications for EV Battery Trays

Battery safety depends on leak-tight, dimensionally stable, and structurally reliable aluminum battery trays. Friction stir welding (FSW) has become a preferred joining process, delivering low distortion, reliable sealing, and high structural strength.

Typical applications include battery trays, battery enclosures, and battery pack housings.

Zhihui supports prototype and volume production with customized engineering and manufacturing solutions.
 

High-Precision FSW Solutions for Lightweight Aerospace Structures

Friction Stir Welding (FSW) is widely used in the aerospace sector due to its high-quality welds, low deformation, and suitability for lightweight materials. It is used in fuselage structures such as fuselage panels, skins, and frames, reducing the use of rivets, lowering weight, and enhancing structural strength and fatigue performance. It is particularly suitable for manufacturing liquid fuel tanks, ensuring sealing, reducing leakage risks, and improving safety. For engine mounts and...

Seamless Welding for Satellites and Spacecraft—Powered by FSW

FSW is extensively used in the space sector, benefiting from its high-quality welding, low deformation, and suitability for lightweight materials. For liquid fuel tanks, FSW ensures sealing, reduces leakage risks, and enhances safety. It is used to manufacture satellite frames and casings, where welding lightweight alloys meets the stringent weight and strength requirements of satellites. It is also used in spacecraft panels and frames, reducing rivet use, lowering weight, and...

Precision Welding for Copper-Aluminum Components in Power Devices

FSW is increasingly used in the electronics and power sector due to its high-quality welding, low deformation, low cost, and suitability for various materials. It is used to manufacture power electronic devices such as IGBT modules and power modules, where welding aluminum and copper alloys results in a small heat-affected zone, improving device reliability and lifespan. It is also used to manufacture radiators and cooling plates, ensuring sealing and enhancing cooling efficiency and...

Seamless Welding for Rail Vehicles—From Roof Panels to Connectors

FSW has inherent advantages in the lightweighting of rail transit vehicles, particularly in vehicle structures such as body panels, roofs, and floors. It reduces the use of rivets, lowers weight, and enhances structural strength and fatigue performance, meeting the stringent weight and strength requirements of rail transit. It is also used to manufacture vehicle connectors, joints, interior panels, and brackets, where welding aluminum alloys results in minimal deformation and...

Seamless Welding for Decks, Bulkheads, and Hulls in Shipbuilding

In shipbuilding, FSW is used to weld hulls, decks, and cabin bulkheads. This welding method reduces the use of rivets, lowers weight, and enhances structural strength and fatigue performance, improving the sealing and safety of hulls and ensuring the safety performance of ships...
FSW Engineering Solutions for High-Performance Aluminum Applications
 
Proven Manufacturing Expertise to Overcome Complex Aluminum Joining Challenges
 

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