How to Save Money When Buying fsw welded parts supplier

When we talk about dedicated FSW machines the price can vary considerably. Starting at 600,000 euros we can obtain an FSW machine that allows us to weld 2 meters long. However, if we need to weld a longer length, this price will be increased. For example, if we need to weld more than 10 meters, the investment would amount to 2 million euros. But why such a high price? The answer is simple: FSW dedicated machines are produced as a single unit (without using mass production principle).

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As for the robot, we must go piece by piece. The robotic arm is mass produced and therefore its price is reduced (about 100,000 euros). Nevertheless, this arm cannot perform FSW welding on its own: an FSW head must be attached to it, it must be integrated through barriers and the entire software environment must be developed. All this, produced in a unitary way, is what will cause a FSW robotic workstation to increase its price, reaching 400,000 euros.

The Stirweld solution consists of adding an FSW head to a machining CNC center, which greatly reduces the cost of investment from the outset. Futhermore, this FSW head is mass produced. For this reason, the cost of the Stirweld FSW head is less than 100,000 euros, a much more advantageous price than the other FSW solutions.

A dedicated FSW machine can apply a very important welding force, normally up to 60 kN. Bearing in mind that 2 kN is equal to about 1 mm of weld thickness, the dedicated FSW machine can achieve up to 30mm.

The welding force of the Stirweld FSW head is 25 kN, which positions it as the intermediate option for this feature. With the FSW head, it is possible to make welds with a thickness up to 12mm and 20 mm in double side weld configuration.

The special FSW machine is manufactured on demand. This means that, once requested, the process of design, construction, assembly, etc. is started from the beginning. Therefore, the delivery time of an FSW special machine is remarkably long: between 12 and 18 months.

The same applies to FSW robot and consequently their delivery time is also long. Normally its delivery time is around 6 months.

However, the manufacturing cycle of the FSW head is very short, so it could be available in just 3 months. In addition, Stirweld has FSW heads in stock, which reduce the delivery time to as little as one month.

In the case of the FSW robot, the accuracy is 1 mm. This low accuracy is due to the low stiffness of the robotic joints and, thus, the important elasticity of serial robots. Consequently, the robot deformations under the high FSW forces cause a lateral FSW tool deviation impacting the weld quality.

A special FSW machine has a very large size and, therefore, it will be necessary to have a large space where to position it.

FSW robot is generally more compact than a special FSW machine. However, it is also necessary to take into account that a space has to be prepared in the workshop to set it up.

In the case of the FSW head, the footprint is almost zero. This is due to the fact that the head is added directly to a CNC machine already in the workshop.

FSW robotic station can also only perform friction stir welding. However, its modularity is considered to be greater, as it could be reconfigured to perform another operation in the future, such as picking.

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The Stirweld FSW head allows the highest level of modularity as it directly transforms the CNC machine into a hybrid machining-welding machine. Since the FSW head is assembled and disassembled in only 10 minutes, it allows access to the CNC machine whenever needed. But it is also possible to carry out small milling operations by simply changing the FSW tool to a milling tool (limited to a speed of rotations per minute).

The performance of a robotic FSW station is not limited, since the robotic arm allows friction stir welding both in front and behind it. In addition, it would be possible to use a rail to move it as much as necessary.

The work envelope of the FSW head is limited by the size of the CNC machine to which it is added. Therefore, with an FSW head it is possible to perform large welds as long as the CNC machine allows it.

When we talk about the FSW head for CNC machine, this feature is directly linked to the CNC machine. If it is a 3-, 4-or 5-axis machine, it will be possible to weld in 3 dimensions. However, this is a more limited movement than a robotic arm.

Why do we do it? Why does Flawless Steel Welding endure the costs of maintaining our AISC certifications? Because we see the value and the results! While not all of the jobs hitting the streets are certified, what a difference there would be if more jobs specified an AISC Certified Company.

Quick Background: The American Institute of Steel Construction was founded in the s to advance the interests of the structural steel design industry in the United States and better serve the overall construction industry. Since then, it has been the leader in research, education, code development, technical assistance, quality certification, and market development for steel construction.

One of the most important roles AISC plays is to certify that steel fabricators and erectors meet a rigorous — and constantly evolving — set of industry standards regarding quality, safety, administration, training, and more.

These certifications are not easy to get. Each takes some time and effort, not to mention expense, in order to qualify and maintain annually — so much so that some companies choose to skip getting certified entirely.

So, what is the benefit of using an AISC Certified Fabricator and AISC Certified Erector? At Flawless Steel Welding (we hold both certifications), we believe there are 5 main ones:

AISC Certified Fabricators and Erectors tend to run more efficiently, since they have consistent processes and formal training procedures as mentioned above. In addition to making things safer, these factors also eliminate wasteful actions and save money — which can be passed down to the end customer through a more reliable and complete quote.

By using fabricators and erectors that pass the rigorous standards established by the AISC, you also prove that our industry can self-police and reduce burdensome government regulations and excessive interference.

While we are obviously a bit biased towards AISC certified firms (since we are one), it really is to your benefit to seek out a certified firm — even if the quote is slightly higher than a competing, non-certified company’s. In going that route, today’s minor savings might just add up to significant costs in the future.
Want to find out more about how our AISC certifications can benefit your next job? Call us today!

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