Friction Stir Welding (FSW) is a solid-state joining process that produces strong, high-integrity welds without melting the material. FSW is used across aerospace, automotive, defence, rail, and energy sectors where traditional welding methods fall short.
A Different Kind of Weld
Unlike conventional welding, FSW doesn’t use high heat to melt metals. Instead, a rotating tool stirs the edges of the material together, using frictional heat and pressure to forge a solid-state bond. The result is a defect-free joint with excellent mechanical properties — especially in hard-to-weld alloys. See how it compares with TIG and MIG and other joining processes.
How Friction Stir Welding works
A specially designed rotating tool is positioned at the joint between two metal parts. The tool shoulder presses down, generating frictional heat without melting the material. The pin stirs and softens the material, mechanically mixing the joint interface. As the tool moves forward, it forges a solid-phase bond along the seam. The tool exits, leaving behind a smooth, high-integrity weld with no filler or porosity.
Why Use Friction Stir Welding?
Stronger Joints — Excellent fatigue and tensile properties
Zero porosity — Gas and water-tight joints
No Filler Material Needed — Reduces weight and complexity
Low Distortion — Minimal heat input compared to traditional welding
Weld Dissimilar Materials — Join aluminium to copper, steel, titanium, and more
Environmentally Friendly — No shielding gas, fumes, or sparks and low energy input
Weld any aluminium alloy — Weld all aluminium alloys (including 2xxx and 7xxx series). Weld Plate, cast or extruded aluminium.
Save time and money — Fast welds, with no pre or post-processing, and no consumables
Where is FSW Used?
Applications Across Advanced Industries Friction Stir Welding is used wherever material performance, safety, and precision are critical. StirLight supports FSW projects in:
If you already own a joining process, the useful question is whether friction stir welding should replace it. Direct comparisons, including where the incumbent remains the better engineering choice, live on the joining process comparisons hub:
Whether you are prototyping, developing a new process, or scaling production, we will help you get there faster with expert Friction Stir Welding support.
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