Advanced Welding & CNC CAM

Friction Stir Welding (FSW) Tooling Calculator

Compute critical FSW pin tool dimensions, shoulder scroll spiral pitch, linear weld advance per revolution (v/N), spindle torque power, and heat index for defect-free solid-state joins.

1. Input Parameters

Plate Joint Thickness t (mm):

Thickness of the abutting aluminum or copper plates to be welded.

Spindle Speed N (RPM):

Rotational velocity of the FSW tool head.

Traverse Feed Rate v (mm/min):

Linear welding travel speed along the joint seam.

Pin Major Diameter d_p (mm):

Diameter of the threaded / fluted probe pin at the shoulder root.

Tool Lead Tilt Angle θ (degrees):

Rearward tilt angle to forge the plasticized stir zone beneath the trailing shoulder.

2. Calculation Results

Rec. Shoulder Diameter (D_s)

15.0 mm

Weld Pitch (Advance/Rev)

0.20 mm/rev

FSW Heat Index (HI)

600

Rec. Pin Length (L_p)

5.70 mm

3. Geometric Visualizer

Tooling & Vector Prepress Engineering Notes

Shoulder-to-Pin Ratio (D_s / d_p): A ratio between 2.5 and 3.5 provides sufficient frictional surface contact to plasticize the workpiece while containing forging pressure without causing flash ejection.

Weld Pitch Window: For standard 6xxx and 5xxx aluminum series, a weld pitch (traverse feed / RPM) between 0.15 and 0.35 mm/rev prevents 'wormhole' tunnel voids (caused by cold stir / insufficient heat) and surface kissing-bond defects (caused by excessive overheating / liquation).