Catalog FSW

the resulting joined metals Friction stir welding requires less energy and does not have a fine grain structure that resists fatigue stress. the metals flow together and become forged. Friction stir welding is a great solution when welding parts with Variables such as force. extremely high quality weld.wordpress. subsequent use. thus assuring that the metals are not melted and that the tool itself is not consumed in the process. innovative engineers with extensive expertise Because the metals are stirred. c o m CA L L F O R A CU ST O M Q U O T E : 8 0 1 . and Advanced Metal Products. MegaStir has also created a unique tool holder that keeps the tips and tool at a steady temperature.org/licenses/by-nc-sa/3. cracking do not occur. rotational speed. With a state-of-the-art. traverse speed and heat are complex geometries. As the tool moves down the weld joint.0/us/ Established in 2002.F R I C T I O N S T I R W E L D I N G T O O L S FRICTION STIR WELDING In the friction stir welding process. Pin panels. M e g a S t i r. toughest welding challenges.45 1 8 02 . reducing the costs associated with preparing the part for welded. normally “unweldable” alloys in tool materials and tool engineering who can create solutions for your Due to the low heat and small heat-affected zone. cylinders and long-length completely monitored and controllable. MEGASTIR IS A PREMIERE TOOL DESIGN & FABRICATION COMPANY SPECIALIZING IN FRICTION STIR WELDING JOINING DISSIMILAR ALLOYS MegaStir has top-notch. contoured parts. MegaStir can meet all of your friction stir GEOMETRIC CHALLENGES DEFECT-FREE welding needs. The rotation of the tool creates enough friction to heat the material to a plastic or doughy state.8 1 8 . Inc. No outside material is used and the resulting weld is made solely of the parent materials. LITTLE DISTORTION A BETTER WELD. with a world-wide customer base. Ecology Icons Set1 by DragonArt A weld that has been made through friction stirring offers numerous advantages: Friction stir welding offers several other advantages over traditional welding: HIGH STRENGTH & TOUGHNESS ENVIRONMENTALLY SOUND Because heat is kept low during the process. two solid metal surfaces are joined by “stirring” the metals together using a spinning tool. prototyping and production facility. therefore. allowing for an optimum weld. there is minimal distortion such as aluminum and stainless steel can be friction stir of the joined parts. MegaStir is a joint venture between Schlumberger Ltd. porosity and produce the fumes and gases of traditional welding. The tool is inserted into the location where the two metals are to be joined. MegaStir has made significant innovations in the friction stir welding process by creating and patenting tool tips made from PCBN to allow friction stir welding of harder metals such as steel and nickel-based alloys. Creator : DragonArt dragonartz. 01 w w w. ISO 9001 certified R&D.com length and geometry are custom-made for the specific application assuring an http://creativecommons. Mg alloys temperature friction stir welding needs. Designed for applications ranging from elastomeric products rated O be joined (i. such as aluminum and aluminum alloys. W B PCBN is an ideal material for high temperature friction stir welding as it possesses excellent toughness plus an exceptionally high value of thermal conductivity and boasts THE BEST thermal stability & hardness. PCBN is an ideal material for high temperature friction stir welding as it possesses excellent toughness plus an exceptionally high value of thermal conductivity and boasts THE BEST thermal stability & hardness.e. MegaStir tools offer unique high friction and durable tool T geometry (i.Flats . R I C T I O N S T I R rotate in contact with the base material.e. stainless steel. MegaStir tools can handle your high L expected life of the tool. To create an optimal a local plasticized region around the tool. little or no porosity. testing of steel and Ti alloys G Al alloys. metal matrix composite. it creates frictional heat. little or no post-weld repair. producing combination of frictional heating and forging pressure. Ni. these elements either alloy with the material being L TOOL DESIGN TOOL MATERIAL niobium. and material thickness. Tungsten Carbide good toughness at low temps Polycrystalline Diamond high wear. make it a premiere material for friction stir welding of high melting point metals. Use this high temperature excellent toughness good hardness ~2000hv for extreme temperatures to pressures in oil and gas wells and aerospace O choosing your tool material. stainless steel. respect to the base material. Tools made after welding only a few centimeters. no solidification cracking. marine. ultra-high pressure presses. forging pressure applied by the tool and the travel speed of the tool with of deformation and the large forging pressures applied by the tool shoulder. improved corrosion resistance. H13 Steel good toughness good strength Al alloys. The process uses tools made from hardened tool steels that are inexpensive to fabricate. plasticized material is displaced around the tool. The MegaStir proprietary solid-state I characteristics are important for each friction stir welding application.Threads . the PCBN/W-Re wear. shoulder and pin diameter). Benefits include low distortion. and transportation industries for many years. Mg alloys MP159 Cobalt highest toughness highest strength highest thickness Al alloys. and your own experiences and preferences. POLYCRYSTALLINE CUBIC BORON NITRIDE (PCBN) PCBN is a synthetic super abrasive material (second in hardness only to diamond) that MegaStir creates in its high temperature. stainless steel. no welding fumes or gases. consider the material of the work piece. especially when combined with ceramics and metals. metal matrix composite Collar LOW-TEMPERATURE FRICTION STIR WELDING Friction stir welding for low-meltingpoint metals. Cu metal matrix composite engines to recreational products. 03 These qualities. The high degree welding application. and lower cost in production applications. but during E TOOL MATERIAL they have posed many challenges from refractory alloys containing tungsten. Ni. M e g a S t i r. greater weld strength. Cu metal matrix composite PCBN formulas. high toughness Pin Shoulder A C Cu. As the tool traverses along the chart to help you determine what tool material may be best for your friction stir friction stir weld. Using its own patented G pieces and the larger concentric “shoulder” which is maintained on the PCBN joining process combines cutting and friction to join high-temperature alloys N MegaStir tools consist of a protruding “pin” which is plunged into the work for friction stir welding. Tool steels S surface of the joint. These parameters are governed by the tool produce a full metallurgical bond. no filler metals. When WELDABLE METALS friction stir welded or abrade and deposit tool material in the weld region D Selecting the correct tool material requires knowing which material PROPERTIES friction stir welding. c o m A Shank Diameter D Pin Base Diameter B Shoulder Diameter E Convex Radius C Pin Length F Pin Angle G Shoulder & Pin Features . w w w. rhenium. you must combine optimal rotational speed of the tool with weld joint.F MELTING POINTS HIGH-TEMPERATURE FRICTION STIR WELDING Because metals such as steel. flow stress). The shoulder has a concave surface. resulting in a superior weld. mechanical properties of material to high temperature high hardness ~3600hv quickly and consistently. When the shoulder and pin steel. hafnium.Other CA L L F O R A CU ST O M Q U O T E : 8 0 1 .8 1 8 . and nickel-based alloys have high melting points. D F E Shank provide sufficient hardness and abrasion resistance at these temperatures. MegaStir has further optimized the abilities of PCBN in its MS-Series and Q-Series tools for the best durability and quality high temperature friction stir welds. which produces a steel.45 1 8 04 .Step Spirals . molybdenum. and zirconium have high-temperature properties. has been used in the aerospace. 38mm. 50mm or custom Pin Length: Up to 25mm Shoulder Diameters: 25mm. the Q Series Tool has the toughest. c o m CA L L F O R A CU ST O M Q U O T E : 8 0 1 . This premium tool welds the toughest and thickest metals at higher temperatures. 50mm or custom Custom Pin Sizes: Contact MegaStir Threading: C4 or MM Custom Pin Sizes: Contact MegaStir Threading: C4 or MM Part Number 05 R Pin Length Part Number Pin Length Part Number Pin Length Part Number Pin Length Part Number Pin Length Part Number Pin Length MS-M-001 1mm MS-M-006 6mm MS-M-011 11mm MS-Q-001 1mm MS-Q-006 6mm MS-Q-011 11mm MS-M-002 2mm MS-M-007 7mm MS-M-012 12mm MS-Q-002 2mm MS-Q-007 7mm MS-Q-012 12mm MS-M-003 3mm MS-M-008 8mm MS-M-019 19mm MS-Q-003 3mm MS-Q-008 8mm MS-Q-019 19mm MS-M-004 4mm MS-M-009 9mm MS-M-020 20mm MS-Q-004 4mm MS-Q-009 9mm MS-Q-020 20mm MS-M-005 5mm MS-M-010 10mm MS-Q-005 5mm MS-Q-010 10mm w w w. 25mm. 50mm or custom Pin Length: Up to 25mm Shoulder Diameters: 25mm. 38mm. M e g a S t i r. most crack-resistant PCBN tip available.I C T I O N S T I R W E L D I N G T O O L S 25mm M Series Tool 50mm M Series Tool Q Series Tool with 50MM shank Q Series Tool with 25mm shank M SERIES TOOL Q SERIES TOOL Longest-wearing polycrystalline cubic boron nitride (PCBN) tip for steel friction stir welding. FEATURES FEATURES Tip Material: PCBN with ceramic binder (highest percentage of PCBN) Shank Material: Tungsten carbide Use: Most steel and stainless steel applications Tip Material: PCBN tungsten rhenium binder Temperature Monitoring Port: Yes Temperature Monitoring Port: Yes Shank Material: Tungsten carbide Hardness: ~2000 Vickers Hardness: ~3600 Vickers Wear: Use when toughness and torque are critical Wear: Longer Use: Nickel-based alloys and higher-strength stainless steels SPECIFICATIONS SPECIFICATIONS Tool Tip: PCBN Shank Size: 1 inch. 25mm. 50mm or custom Tool Tip: Q Series PCBN Shank Size: 1 inch. 38mm.45 1 8 H I G H M E LT I N G P O I N T W E L D I N G H I G H M E LT I N G P O I N T W E L D I N G F 06 . This tool works great for most steel welds at higher temperatures.8 1 8 . 38mm. Made from PCBN with tungsten rhenium binder. 8 1 8 . 50mm or custom Shank Size: 1 inch.I C T I O N S T I R W E L D I N G T O O L S H13 1-inch tool D Series Deburr Tool H13 20mm tool D SERIES TOOL H SERIES TOOL This time-saving tool provides deburring. 38mm. 25mm. 38mm. Solid. 25mm. it finishes the weld without any extra processing time. 50mm or custom Custom PinSizes: contact MegaStir Custom Pin Sizes: contact MegaStir Threading: C4 or MM Shoulder Diameters: 25mm. 50mm or custom Part Number 07 R L O W M E LT I N G P O I N T W E L D I N G H I G H M E LT I N G P O I N T W E L D I N G F Pin Length Part Number Pin Length Part Number Pin Length Part Number Pin Length Part Number Pin Length Part Number Pin Length MS-M-001 1mm MS-M-006 6mm MS-M-011 11mm MS-H-001 1mm MS-H-006 6mm MS-H-011 11mm MS-M-002 2mm MS-M-007 7mm MS-M-012 12mm MS-H-002 2mm MS-H-007 7mm MS-H-012 12mm MS-M-003 3mm MS-M-008 8mm MS-M-019 19mm MS-H-003 3mm MS-H-008 8mm MS-H-019 19mm MS-M-004 4mm MS-M-009 9mm MS-M-020 20mm MS-H-004 4mm MS-H-009 9mm MS-H-020 20mm MS-M-005 5mm MS-M-010 10mm MS-H-005 5mm MS-H-010 10mm w w w. 38mm.45 1 8 08 . c o m CA L L F O R A CU ST O M Q U O T E : 8 0 1 . good wear Operation System: Pivotol or fixed cutter Temperature Monitoring Port: N/A Use: Aluminum and magnesium welding Use: High temperature applications Hardness: Same as Q or M Series Temperature Monitoring Port: No SPECIFICATIONS SPECIFICATIONS Tool Tip: Q or M Series PCBN Shank Size: 1 inch. one-piece tool made from H13 offers all-around good wear. FEATURES FEATURES Tip Material: Q or M Series PCBN Purpose: Cleans flash without interfering in weld process Tool Material: Standard H13 tool steel (combined shank/tip) Shank Material: Tungsten carbide Compatibility: MegaStir liquid-cooled tool holder Wear: Economical. Attached directly to the MegaStir tool. 38mm. burnishing and milling during the welding process. 50mm or custom Shank/Tip: H13 tool steel Threading: C4 or MM Pin Length: Up to 25mm Shoulder Diameters: 25mm. M e g a S t i r. this tool has the hardest tip available. 38mm. 25mm. 38mm.45 1 8 L O W M E LT I N G P O I N T W E L D I N G L O W M E LT I N G P O I N T W E L D I N G Material: Solid Tungsten Carbide Wear: Higher in softer metals (MMCs). Provides a high quality weld while keeping the metals as cool as possible. FEATURES SPECIFICATIONS A Series Adjustable Tool A SERIES TOOL S Series Standard Tool MS-T-009 9mm MS-T-010 10mm FEATURES MS-T-004 4mm MS-T-011 11mm Tip Material: MP159 MS-T-005 5mm MS-T-012 12mm Shank/Shoulder Material: H13 MS-T-006 6mm MS-T-019 19mm Use: Interchangeable pins with different design features and MS-T-007 7mm MS-T-020 20mm SPECIFICATIONS Material: Solid MP159 (nickel-cobalt based multiphase alloy) Tip: MP159 Use: Thicker aluminum welds Shank/Shoulder: H13 Temperature Monitoring Port: No Shank Size: 1 inch. 38mm. c o m Pin Length Part Number CA L L F O R A CU ST O M Q U O T E : 8 0 1 . 38mm. 50mm or custom Shoulder Diameters: 25mm. higher abrasive aluminums and magnesium Thermal Conductivity: Higher than H13 or MP159 (pulls more heat from the metal) Pin Length 10 . 50mm or custom Shoulder Diameters: 25mm. 25mm. 25mm.8 1 8 . 50mm or custom Threading: C4 or MM Custom Pin Sizes: contact MegaStir SPECIFICATIONS Custom Pin Sizes: contact MegaStir Threading: C4 or MM Part Number Pin Length MS-A-001 1-3mm MS-A-004 4-6mm MS-A-007 7-9mm 09 FEATURES Shoulder Diameters: 25mm. 50mm or custom Part Number MS-T-002 2mm adjustable lengths to allow for flexibility in welding Shank/Tip: Solid MP159 Pin Length MS-T-008 8mm S Series 25mm Tool Excellent tip for higher strength or thicker aluminum welds. thermal-conductive tool. 38mm. 25mm. 50mm or custom Shoulder Diameters: 25mm. 38mm. 50mm or custom Threading: C4 or MM Custom Pin Sizes: contact MegaStir Part Number Pin Length Part Number Pin Length Part Number Pin Length MS-A-010 10-12mm Part Number MS-S-001 1mm MS-S-006 6mm MS-S-011 11mm MS-A-013 13-15mm MS-P-001 1mm MS-P-008 8mm MS-S-002 2mm MS-S-007 7mm MS-S-012 12mm MS-A-016 16-19mm MS-P-002 2mm MS-P-009 9mm MS-S-003 3mm MS-S-008 8mm MS-S-019 19mm MS-P-003 3mm MS-P-010 10mm MS-S-004 4mm MS-S-009 9mm MS-S-020 20mm MS-P-004 4mm MS-P-011 11mm MS-S-005 5mm MS-S-010 10mm MS-P-005 5mm MS-P-012 12mm MS-P-006 6mm MS-P-019 19mm MS-P-007 7mm MS-P-020 20mm w w w. FEATURES Pin Length: Up to 25mm Pin Length MS-T-003 3mm different alloys and thicknesses Shank Size: 1 inch. 38mm. 38mm. S SERIES TOOL Shank Size: 1 inch. Part Number MS-T-001 1mm Excellent option for higher strength or thicker aluminum welds with adjustable pins.F R I C T I O N S T I R W E L D I N G T O O L S T SERIES TOOL Long-wear. 50mm or custom Threading: C4 or MM Custom Pin Sizes: contact MegaStir Tip: PolyCrystalline diamond (~4000 Vickers hardness) Shank: Tungsten carbide Application: Low temperature or abrasive applications in lower melt materials (aluminums) SPECIFICATIONS Pin/Shoulder: PolyCrystalline diamond Shank Size: 1 inch. 50mm or custom P SERIES TOOL Used for extreme wear in low temperature applications. M e g a S t i r. FEATURES • Offers exclusive steady-state temperature system with argon shielding ports and gas shroud. connections.38mm collet for English sized tools MS60011 50mm . Tool holder not required. 11 w w w.45 1 8 12 . SPECIFICATIONS Compatible with all MegaStir friction stir welding tools.F R I C T I O N S T I R W E L D I N G T O O L S TELEMETRY SYSTEMS Provides real-time temperature and load monitoring of the friction stir welding tool. Also fits other-party tools of standard size. 50 mm and 1 inch shanks. SPECIFICATIONS Compatibility: MegaStir liquid-cooled tool holder Tool Holder Collet Part Number Liquid Cooled Tool Holder LIQUID-COOLED TOOL HOLDER The MegaStir Tool Holder uses a patented liquid cooling system which pulls the heat from the tool. M e g a S t i r. PART NUMBER DESCRIPTION MS60201 Tungsten carbide friction stir spot welding tip holder with custom tip. c o m CA L L F O R A CU ST O M Q U O T E : 8 0 1 . • Offers a second channel load cell (optional) for monitoring and control of downward force during welding. Does not build up heat like other tool holders. • Available in 25 mm. spot welds. Specify 10 or 12 mm shoulder size. TOOL HOLDER COLLET Adapter for MegaStir liquid-cooled tool holder. 16 mm shank standard (custom sizes on request). M Series or Q Series tip material and pin size. keeping it at a steady temperature. allowing for better quality welds and improved tool life. Drawbar connections available in English and metric threaded • Accepts all MegaStir tools as well as the proprietary Description MS60101 Single channel temperature monitoring telemetry system MS60102 Double channel temperature and load monitoring telemetry system FRICTION STIR SPOT WELDING TOOL Designed for small. Specify shoulder size. Specify M Series or Q Series tip. Custom pin lengths and shank sizes also available. FEATURES • Fits onto the MegaStir Tool Holder and monitors the K-type thermocouple which is inserted into the friction stir welding tool. • Allows you to make adjustments to the welding process to maintain proper temperature of the metals. telemetry system and deburr tool. Part Number Description MS6001 MDM50-2500 liquid-cooled tool holder for metric sized tools Part Number Description MS6002 IDM50-2500 liquid-cooled tool holder MS60010 50mm .8 1 8 .25mm collet SOLID UNIT • Low temperature applications • Available as a single solid tungsten carbide unit TOOL HOLDER & TIPS • Higher temperature steel applications • Comes with a smaller steel tool holder and separate tips from M Series or Q Series material SYSTEM COMPONENTS SYSTEM COMPONENTS Telemetry System SPOT WELDING TIPS • M Series or Q Series material PART NUMBER PIN LENGTH DESCRIPTION MS45014 .5mm Solid friction stir spot welding unit made from tungsten carbide with 16 mm shank and PCBN tip. Custom pin lengths available. the friction stir spot welding tool is smaller than the full-size friction stir welding tools and is available for both low and high temperature welding. Friction stir spot welding tools are available in 10mm and 12mm shoulder sizes. • Fits standard CAT #50 tapered spindles. stainless steel.TOP INDUSTRIES SERVED BY FRICTION STIR WELDING MegaStir offers the latest in friction stir welding tools and technology. Controlling the temperature of both the tool and the weld is critical in order to maintain tool integrity and weld strength. Because concentricity and run-out are key elements in MegaStir engineers are highly skilled and constantly engaging in new research friction stir welding. MegaStir has a full metallurgical lab and testing services. which are produced around the outer surface of a cylindrical piece and are used to fabricate structural pipes. from R&D through prototyping. all MegaStir tools have a receptive port for the MegaStir has full prototyping facilities with engineers on staff to develop and thermocouple near the tool tip. MegaStir also specializes in circumferential welds. force. friction bit joining is a proprietary even when welding at higher temperatures. tool and material temperature. MegaStir offers a variety of friction stir welding production services. and full production. and nickel-based alloys. single-pass friction stir welds up to 25 mm in thickness. friction spot welding technique developed by MegaStir. technology. tool materials and the friction stir welding process. alloy development. Since PCBN is the second-hardest material then joins the parts together. combined with high end machinery allows for a wide range of capabilities—from simple plate welding for TECHNOLOGY MANUFACTURING mechanical and metallurgical samples to long welds and complex geometries. high strength welds in a single pass. hardness and tip material so consumable bit. the joining machines and consumable bits for custom tasks based on its patented MegaStir patented PCBN tips let you friction stir weld the hardest steel. extending current limits. MegaStir designs and builds friction bit material on earth and is thermally stable at elevated temperatures. It uses a MegaStir tools come in a wide variety of sizes. temperature control. The thermocouple wire from the tool holder slides into the tool itself. consistently produce top quality. friction bit joining machines or any other friction stir welding machine for your MegaStir tools let you manage your welds through position. c o m Annette Jenkins Product Manager Dale Fleck General Manager CA L L F O R A CU ST O M Q U O T E : 8 0 1 . With its proprietary cooling design. M e g a S t i r.8 1 8 . THE MEGASTIR CORE TEAM OIL & GAS OCEAN TRANSPORT FULL PRODUCTION FRICTION STIR WELDING MegaStir’s expertise in friction stir welding. This method is used AEROSPACE to join steels and dissimilar metals. and GROUND TRANSPORTATION specific job. which transmits the torque from the shank through the tool tip. including aluminum to steel. MegaStir tools including aluminum. steel. With a PROTOTYPING thermocouple in the tool holder. so you can monitor and maintain temperature while ENGINEERING AND R&D the tool is rotating. MEGASTIR PRODUCTION SERVICES Contact MegaStir for your production and custom machinery needs. the MegaStir tool holder draws FRICTION BIT JOINING heat away from the tool and keeps the tool at a steady temperature. More economical CUSTOM MACHINES tools are available for aluminum and lower temperature welding. Friction stir welding services are offered for all alloys. They are also available for custom R&D and engineering projects. Used primarily in the automotive industry. and are continuously 13 Russell Steel Director of Business Development w w w. that first cuts through a specific you can get the perfect tool for the job. MegaStir can provide full-penetration and partial-penetration. stainless steel and nickel-based alloys. MegaStir uniquely offers a friction stir spot welding tool for high temperature applications as well. all MegaStir tools have a precision tungsten carbide shank and development of tools. resembling a welded rivet. Designed for endurance and quality welding.45 1 8 14 . allowing for a highly accurate reading of both prototype parts and components. MegaStir can design and build oil pipeline friction stir welding machines. call: 801-818-4518 email: megastircs@slb. . UT 84604 © 2014 MegaStir | All Rights Reserved.MegaStir.com www.com 275 West 2230 North Provo. MegaStir is a joint venture of Schlumberger and Advanced Metal Products.