GOLDEN RULES OF FRICTION STIR WELDING DESIGN

DESIGN GUIDELINES FOR DIE CASTS WELDED BY FSW

Maximize the performance of your die cast assemblies with our complete Design Guidelines for FSW. This guide gives you a clear and practical framework to design die cast parts that are fully compatible with Friction Stir Welding, with content ranging from process fundamentals to detailed design rules and a real industrial case study.

Discover how to reduce defects, secure weld quality and avoid costly redesigns thanks to recommendations built on real project experience. Request the guide through the form and gain the technical confidence you need to integrate FSW into your die cast parts.

Design guideline for friction stir welded die casts

 

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DETAILED SUMMARY

What will you find in these Design Guidelines for die castings?

By downloading this free guide, you will access exclusive insights to understand how to apply Friction Stir Welding to die cast parts. This guide covers all essential aspects, from process fundamentals to detailed design rules applied to die casting parts.

Stirweld triangle

INTRODUCTION TO FSW AND DIE CASTINGS

This section explains the four key stages of the Friction Stir Welding process and presents the main technical advantages of using this technology on die cast components. You will learn that FSW is one of the most reliable solutions for high performance welds, improving mechanical strength, sealing capability and fatigue resistance.

Stirweld triangle

DESIGN GUIDELINES, PARAMETERS THAT MATTER

The core of the guide provides clear and practical recommendations to help engineers design die cast parts fully compatible with FSW. You will learn how to define mechanical requirements, how to select relevant material properties for simulation and how to integrate key parameters such as tool selection, weld penetration and geometric constraints into your design process.

Stirweld triangle

PART DESIGN RECOMMENDATIONS

This section details the rules that ensure stable and high-quality welding, including thickness requirements, radius constraints, path accessibility and other specific features needed to support the welding force. You will also find guidance on designing robust load support areas and backing features to guarantee consistent welding results.

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CASE STUDY, APPLYING THE GUIDELINES TO A REAL DIE CAST

To help you translate theory into practice, the guide includes a complete example based on an industrial heat sink welded by FSW. From initial specifications to alloy selection, mechanical calculations, welding configuration and final part design, allowing you to understand exactly how the guidelines apply to a real component.