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The customer initially used TIG welding (Tungsten Inert Gas welding) for busbar welding, but encountered issues such as low efficiency, environmental pollution, and high costs. To address these challenges, Dongguan Zhihui Welding Technology Co., Ltd. collaborated with the customer to design and develop a customized friction stir welding (FSW) device, which significantly improved the performance of the customer's products.
Good electrical conductivity.
Elimination of the need for beveling the base material.
Savings on welding consumables: no need for welding wire, argon gas, or graphite plates.
High-quality welds: high mechanical properties, no porosity, no cracks, minimal distortion.
Improved working environment: no smoke, no intense light.
Simple and convenient operation; employees do not require welding certification.

Comparison of 2 welding process on same product

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Introduction To Customized Services

Introduction To Customized Services

Core Customized Service Content

Personalized customization of stir friction welding equipment

Scenario adaptation design: Customize the shape, size and mechanical structure of the stirring head according to customer welding requirements (such as material type, workpiece size, welding efficiency).
Process parameter optimization: Provide intelligent matching solutions for parameters such as welding speed, downforce, rotation speed, etc. to ensure that the welding strength is ≥ 85% of the parent material.
Multi-axis linkage system: Develop a multi-axis collaborative control module for complex curved surfaces or special-shaped workpieces to achieve automatic welding path planning.

Special research and development of special welding tools

Material adaptation tools: Customize high-temperature resistant and high-wear resistant stirring heads and fixtures for difficult-to-weld materials such as aluminum alloys, titanium alloys, and composite materials.
Lightweight design: Develop lightweight welding tools for scenarios such as new energy vehicle battery trays and mobile phone precision structural parts to reduce equipment load.
 

Full-process technical solutions

Pre-welding process verification: Optimize process parameters and reduce trial and error costs through simulated welding experiments.
Quality monitoring during welding: Integrate real-time temperature and pressure monitoring systems to ensure the stability of the welding process.
Post-weld performance testing: Provide non-destructive testing, metallographic analysis and other testing services, and issue authoritative reports.

Cooperation Model

Cooperation model

Technology co-creation: Deeply cooperate with the customer's R&D team, share the technical resources of CFSW center, and overcome industry technical problems.
Intellectual property sharing: The results of cooperative development can be negotiated to apply for patents to protect the customer's technical rights and interests.
 

Turnkey engineering model

One-stop service: From equipment design, manufacturing, commissioning to personnel training, the entire process is responsible by the Zhihui welding team.
Fast delivery: Relying on the standardized module library, shorten the customization cycle to 45-60 days (regular projects).
 

Long-term technology hosting model

On-site service: We provide on-site technical support services by engineers for customers to solve production problems in real time.
Regular upgrades: According to the needs of technical iterations, provide customers with equipment software/hardware upgrade services free of charge during the quality guarantee period.

Introduction to Customization Process

  • Demand communication and confirmation
     Customer consultation: Customers contact us by phone, email or online platform to put forward preliminary customization requirements.
     Demand research: Our professional team communicates with customers in depth to understand their specific needs, including welding materials, workpiece size, welding accuracy, production efficiency and other requirements.
     Demand document preparation: Based on the communication results, we prepare detailed demand documents to clarify the specific content and requirements of customized services.
    Demand confirmation: Review the demand documents with customers to ensure that both parties have a consistent understanding of the requirements and sign to confirm.
  • Scheme design and optimization
     Preliminary scheme design: According to customer needs, our technical team formulates a preliminary customization plan, including equipment selection, mixing head design, process parameter setting, etc.
     Internal review: Organize internal experts to review the preliminary plan to ensure the technical feasibility and economic rationality of the plan.
     Scheme optimization: According to the review opinions, optimize and adjust the plan until it meets customer needs.
    Scheme submission: Submit the optimized plan to the customer for further communication and confirmation.
  • Manufacturing and debugging
     Production Plan Formulation: According to the confirmed customization plan, formulate a detailed production plan, including raw material procurement, parts processing, equipment assembly, etc.
     Manufacturing: Carry out manufacturing according to the production plan to ensure product quality and delivery time.
     Equipment Debugging: Before the equipment leaves the factory, conduct comprehensive debugging and testing to ensure that the equipment performance is stable and reliable.
    Customer Acceptance: Invite customers to conduct on-site acceptance of the equipment to ensure that the equipment meets customer needs.
  • After-sales service and support
     Technical Training: Provide customers with technical training in equipment operation, maintenance, etc. to ensure that customers can use the equipment proficiently.
     Technical Support: Provide 7×24 hours of technical support services to promptly answer questions encountered by customers during use.
     Regular Return Visits: Regularly return visits to customers to understand the use of equipment and provide necessary maintenance and upgrade suggestions.
    Long-term Cooperation: Establish long-term cooperative relationships with customers and continue to provide high-quality customized services and technical support.
  • Customization process features
     Flexibility: Personalized customization according to the specific needs of customers to meet the unique needs of customers.
    Professionalism: Relying on the technical resources and expert support of     CFSW center, we ensure the professionalism and reliability of customized services.
     Efficiency: Through standardized module libraries and flexible production capabilities, we shorten the customization cycle and improve production efficiency.
    Comprehensiveness: We provide full-process customized services from demand communication, solution design, production and manufacturing to after-sales service to ensure that customers can use it without worries.

Introduction to Customizable Scope​​​​​​​

  • Customization of friction stir welding machine
  • Customization of friction stir welding tools
  • Customization of welding process parameters
  • Application scenario customization
  • Customization of CNC equipment

After-sales service and technical support customization

Training plan: Customized training plans for equipment operation and maintenance according to the actual needs of customers.
Technical support plan: Provide remote technical support, on-site service, regular return visits and other technical support solutions to ensure that customers get timely and effective help during use.
Dongguan Zhihui Welding Technology Co., Ltd. with its rich technical experience and professional invovation technical team, can provide customers with full-process customized services from demand analysis, solution design, production and manufacturing to after-sales service. We are committed to becoming a trusted partner of customers and jointly promote the development and application of stir friction welding technology.
The company is dedicated to providing customers with one-stop services in the field of special welding, ranging from intelligent equipment, advanced manufacturing, welding consumables to technical service support.

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Landline: +86-769-8278-1216
E-mail: brad.wang@alcu-fsw.com
              zoey.zhang@alcu-fsw.com
Phone: +86-156-3608-6589 / +86-135-4472-5331
Add: Buliding C, Jinshi Technology Park, Dalingshan Twon, Dongguan, Guangdong, China
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