FRICTION STIR WELDING

Revolutionising the joining of aluminium and steel

With decades of research and development expertise in superhard tooling, we are at the forefront of friction stir welding (FSW) technology. Our end-to-end manufacturing capabilities span material design and synthesis, through to finished tool production, ensuring full control over quality and performance. Our controlled powder preparation delivers consistent and repeatable results, while our commitment to continuous innovation enables ongoing optimisation of both material quality and tool geometry.

Key Benefits of FSW

Friction stir welding delivers significant advantages over conventional welding methods, including high-strength, defect-free joints and faster joining speeds that improve productivity.

It enables the joining of high-strength steels and aluminium as well as other dissimilar materials, while reducing rework and improving weld consistency. Lower overall costs and reduced downtime, due to longer tool life, to make FSW a highly efficient and more environmentally-friendly solution.

In addition, it supports lightweighting through the use of thinner materials and enables automation, even for complex weld geometries.

Synthetic diamond composite tools for joining aluminium

Our synthetic diamond composite FSW tools are engineered for high-performance aluminium welding in structural, aerospace and automotive applications.

They deliver high-quality, low-porosity welds without fillers, with excellent surface finish, fatigue strength and corrosion resistance. Compatible with 2xxx-7xxx and cast alloys, including dissimilar joints, these solutions have proven tool life up to 10 km and speeds up to 6 m/min, maximising productivity with no fumes, gases or consumables.

Synthetic diamond composite tools

PCBN tools for joining steel

Our polycrystalline cubic boron nitride (PCBN) FSW tools are engineered for demanding steel welding applications across multiple industries. Proven on stainless steels, high-strength steels and dissimilar materials, they deliver reliable, world-leading performance. With tool life of up to 65 m weld length and 30 plunges in 6 mm steel, they offer exceptional durability.

Available in sizes from 0.5–15 mm, they are suitable for plate thicknesses from 0.8–30 mm, including specialised applications such as underwater welding.

Synthetic diamond composite tools for welding aluminium

DISCOVER E6’S FSW TOOL SOLUTIONS

Automotive manufacturing

In the automotive sector, friction stir welding is used for EV battery trays and enclosures where strength, weight reduction, and consistency are critical.

Our solution enables defect-free joints in lightweight materials, supporting improved vehicle efficiency, enhanced safety, and high-volume, repeatable production.

Automotive manufacturing

Shipbuilding

For shipbuilding, friction stir welding supports large-scale structural joining where durability and reliability are essential.

Our tooling provides strong, low-distortion welds across thick sections, improving structural integrity while reducing rework and overall build time.

Shipbuilding

Pipeline drilling

In the energy sector, pipeline applications require high-integrity joints that can withstand extreme environments.

Our solution delivers robust, defect-free welds in high-strength materials, ensuring long-term performance, safety, and reduced maintenance in critical infrastructure.

Energy drilling

Aerospace manufacturing

Aerospace applications demand lightweight, high-strength assemblies with absolute precision.

Our FSW technology enables the joining of advanced and dissimilar materials, reducing weight while maintaining structural performance and meeting stringent industry standards.

Aerospace manufacturing

Enabling the Future of Joining

Friction Stir Welding is rapidly becoming the preferred solution for advanced manufacturing. With our expertise in material science, tooling design and application support, we enable customers to achieve higher performance, lower costs, and greater manufacturing efficiency.

Contact our FSW team today and discover how we can optimise your welding processes.