Weld aluminium, titanium and dissimilar alloys without ever melting them. Zero porosity. Near-zero distortion. FSW produces joints the aerospace and EV industries trust for their most critical structures.
A rotating tool with a profiled pin plunges into the joint line between two clamped workpieces. Friction between the spinning shoulder and the metal surface generates heat — but never enough to melt. The plasticised material is stirred and forged as the tool traverses along the joint.
The result is a continuous solid-state bond with grain structure finer than the parent material, virtually no heat-affected zone, and zero solidification defects. FSW eliminates the fundamental problems of fusion welding by never passing through the liquid phase.
ETA's FSW machines support custom tool design — geometry, material and cooling can be optimised for your specific material combination. We also offer feasibility studies, small-batch contract manufacturing, and part qualification support.
| Property | FSW | MIG / TIG |
|---|---|---|
| Porosity | None | Possible |
| Distortion | Minimal | High |
| Solidification cracks | None | Risk |
| Fumes & spatter | None | Yes |
| Filler material | Not needed | Required |
| High-strength Al alloys | Weldable | Very difficult |
| Dissimilar alloys | Yes | Difficult |
| Energy use | Low | High |
Porosity, solute redistribution, solidification cracking, liquation cracking — all eliminated because the process never reaches the melting point. Critical for aerospace aluminium alloys.
Low heat input means EV battery trays and aircraft panels emerge from the machine dimensionally correct — no post-weld straightening, no expensive rework cycles.
High-strength 2xxx and 7xxx aluminium series, Al–Cu, Al–Mg and titanium — materials that conventional welding cannot reliably join are routinely welded by FSW.
No shielding gas, no filler wire, no fumes, no spatter. Eco-friendly process that reduces material consumption and workplace hazards simultaneously.
Once welding parameters are qualified, FSW delivers the same weld every time. Ideal for high-volume production where batch-to-batch consistency is non-negotiable.
ETA offers standalone machines, fully automated cells, small-batch contract manufacturing, and part re-engineering/qualification support — one partner for the full journey.
All machines follow an Engineer-to-Order process. Specifications adapt to your job size, material and production requirement.
Rigid gantry frame with servo-controlled spindle. The workhorse for aluminium panel, EV battery tray and heat exchanger welding. Accommodates a wide range of joint geometries — butt, lap, T-joints.
For large-scale structures requiring high-strength defect-free welds across significant lengths. Ideal for ship hull panels, aircraft fuselage sections, wind turbine blades and railway coach bodies.
Battery trays, battery enclosures, heat exchangers, aluminium chassis, Al–Cu bus bars for EV systems, motor housings
Aircraft fuselage panels, wing stringers, cryogenic fuel tanks, high-strength aluminium structural joints — for ISRO and HAL programmes
Ship hull panels, superstructure plates, deck components — replacing riveting and fusion welding for weight reduction and strength
Rail coach bodies, aluminium floor panels, structural sections — high-strength joints without the distortion of fusion welding
Wind turbine blade sections, nuclear component assemblies, power electronics heat sinks and cooling plates
Any application requiring defect-free joins in aluminium, titanium, copper, magnesium or dissimilar metal combinations
Bring us your material, joint geometry and quality requirements. We'll assess feasibility and tell you exactly what machine — or contract manufacturing service — fits your need.