PTG to roll out upgraded stir welding FSW machines for the aluminium extrusion sector

Headquartered in Rochdale, UK, Precision Technologies Group (PTG) is yet to launch its series of Powerstir dual weld-head friction stir welding (FSW) machines after the success of their dual-head FSW machines released about two years ago. Designated especially for applications in mass manufacturing of automotive battery tray floor assemblies from extruded aluminium panels, PTG’s dual-head FSW machines were a big hit among the electric vehicle OEMs sector.

The company’s dual weld-head method is beneficial for skate chassis manufacturers and guarantees a compact weld-flatness during the construction of the battery tray floor.

A compact weld-flatness tolerance of the battery floor is necessary since the battery must sit perfectly clasped within its housing and the PTG dual weld-head method provides that. The company’s innovation decreases post-weld distortions and provides each welded assembly with a substantially improved flatness tolerance if comprised of prevailing single-side FSW processes.

Precision Technologies Group’s sales director, Mark Curran exclaimed: “Since our Powerstir dual weld-head FSW machines were introduced in 2020, they have achieved double-digit sales – quite an accomplishment during such a challenging trading period for the manufacturing industry, and testimony to the quality of the technology.”

PTG is acknowledged broadly as a leader in the evolution of FSW technologies for vehicular applications. The manufacturers of aerospace components and aluminium carriage panels for high-speed trains were among the primary admirers of Powerstir friction stir welding.

PTG mainly experiments with 5000 & 6000 series aluminium alloys and magnesium alloys of 3mm to 6mm thickness developing new FSW methodologies for various automotive OEMs.

“In the PTG Powerstir dual weld-head FSW process, typically four to 12 individual child-part extrusions are brought together for assembly. Following gantry loading, each extrusion is automatically positioned and clamped ready for friction stir welding, after which the partially completed vehicle component is automatically repositioned, ready for the next panel to be welded in place,” Curran added.

PTG is also developing FSW techniques for the manufacturing of control box panels, car body panels and coolant units while making Powerstir machines designated for the production of battery tray floor assemblies. The company is progressing in the creation of components and body panels for use in commercial vehicles. The company’s latest stir welding research centre is also aiding various institutions in preparing FSW methods for specific production challenges.

“Our dual weld-head FSW techniques, whereby both sides of an extrusion are welded simultaneously, not only remove the time-consuming process of lifting and turning extrusions between welds but also allow for equal heat dispersion which results in minimal distortion,” Mr Curran narrated.

PTG has been a well-known name for the production of friction stir welding machine tools for transport applications for two decades, once it first launched its Powerstir FSW machine in 1998.

However, PTG now has vouched to share its wisdom regarding the FSW process to help automotive OEMs in manufacturing lightweight, sturdy yet aesthetic components for plug-in hybrid electric vehicles (PHEV) and battery electric vehicles (BEV).

PTG will exhibit its new range of Powerstir dual weld-head friction stir welding (FSW) machines at the Aluminium 2022 programme which is scheduled to be held during 27-29 September, this year, at the Exhibition Centre at Dusseldorf.

“At Aluminium 2022, we look forward to showing the advantages of our dual weld-head approach to OEMs looking to benefit from advanced FSW processes,” Mark Curran concluded.