Mazak MegaStir Friction Stir Welding (FSW) Kits

FSW kits are combinations of tool holders, instrumentation and pin tools for either high- or low-temperature applications. Choose from an Instrumented Tool Holder Kit, Instrumented Liquid-Cooled Tool Holder Kit or an retrofittable FSW Aftermarket Kit.

Instrumented Tool Holder Kit

The FSW Instrumented Tool Holder is an all-in-one tool holder and telemetry system that offers the ability to use FSW on Mazak machine tool platforms. The system collects tool temperature, Z-axis load, and data wirelessly for fine-tuning the FSW process, while analog outputs enable integration with MAZATROL Smooth controls for temperature or force-based algorithmic control of the process.

Features:

  • Wireless telemetry system allows for real-time welding process adjustments using a K-type thermocouple inserted into the FSW tool.
  • Works as a stand-alone device or in combination with a PC via a USB interface for added utility.
  • Up to eight analog outputs for PID control including output replicates.
  • Fully integrated with Mazak MAZATROL Smooth CNC technology for a complete closed-loop software solution.

 

Specifications:

  • Maximum load capability – 6,000 lbf (26.6 kN)
  • Maximum spindle speed – 4,000 rpm
  • Wireless frequency – 2.4 GHz IEEE 802.14.4 compliant
  • Analog output – 8-channel analog outputs (0-3vDC)
  • Temperature sample rates – 64 hertz
  • Load sample rates – 512 hertz
  • Tool shank size – 25 mm diameter
Tool Holder Kit

Instrumented Liquid-Cooled Tool Holder Kit

For increased accuracy and process security, the FSW Instrumented Tool Holder with a liquid-cooled variant provides all the same integrated features with the addition of advanced temperature-control capabilities. Liquid cooling ensures the longest tool life and the strongest possible welds, especially in high-temperature applications or those performed with softer FSW pin materials.

Specifications:

  • Maximum load capability – 20,000 lbf (88.9 kN)
  • Maximum spindle speed  – 1,000 rpm
  • Wireless frequency – 2.4 GHz IEEE 802.14.4 compliant
  • Analog output – 8-channel analog outputs (0-3vDC)
  • Temperature sample rates – 64 hertz
  • Load sample rates – 512 hertz
  • Tool shank size – 25 mm diameter
Liquid-Cooled Tool Holder Kit

Retrofittable Friction Stir Welding (FSW) Aftermarket Kit

Transform existing Mazak Vertical Machining Centers into HYBRID Multi-Tasking machines with the Mazak MegaStir Friction Stir Welding Aftermarket Kit. This retrofittable kit includes an FSW Intelligent Tool Holder, an Industrial Internet of Things (IIoT) wireless gateway and easily accessible closed-loop software.

FSW Intelligent Tool Holder

  • Collects tool temperature, Z-axis load, and other information for fine-tuning the FSW process.
  • Compatible with a comprehensive range of standard or custom non-consumable pins for common materials including aluminum, steel, stainless steel and nickel-base alloys.
  • A WSDA®-Base-101 gateway provides seamless communication between the tool holder’s multiple remote wireless nodes and Mazak MAZATROL Smooth CNCs.

 

Closed-loop FSW software

  • Available through Mazak MAZATROL Smooth CNCs.
  • Allows for real-time process monitoring, manual thrust offset capabilities, process logging and part-program design at the machine control.
  • Easily manage the three main FSW processes – plunging, traversing and extracting – via EIA/ISO or conversational programming within the user-friendly and familiar Mazak MAZATROL Smooth CNC interface.
friction stir welding