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Robotic friction stir welding

Customer-specific, turnkey solutions for joining non-ferrous metals with a low melting temperature and also for mixed-material combinations such as aluminum and steel.

Individual friction stir welding systems for maximum cost-effectiveness and process reliability

For robot-based friction stir welding KUKA offers you custom-tailored complete solutions from a single source: from feasibility and process investigations to trial welds, tool selection and parameter optimization, including the conceptual design, manufacture and delivery of the system.

Furthermore, we offer you all processes for integrating friction stir welding techniques into existing production facilities – adapted to your individual requirements.

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Decisive advantage of robot-based friction stir welding: joining of 3D seams on small and large aluminum components

  • For welding complex 3D seams  
  • Use of high-payload and heavy-duty robots with process-specific expansions 
  • Suitable for joining thin-walled non-ferrous metals 
  • Large workspace, can be expanded by means of linear axes
  • Low investment costs
Robot-based friction stir welding: low-cost and weight-saving alternative to conventional riveting methods

Revolutionary control technology and process monitoring made by KUKA

We use sophisticated calibration algorithms to ensure that the weld is always executed exactly. They additionally facilitate the fast and simple setup of the system. Internet-based KUKA RemoteService is integrated in all systems as standard in order to allow prompt assistance in the event of a fault.

The new KUKA PCD (Process Control and Documentation) system was specially developed for continuous-path FSW processes. Besides component and product data management it offers numerical and graphical parameter monitoring. Data export, process diagnostics and electronic archiving of all process data round out the functionality of the KUKA PCD and allow further analyses, for example in cloud systems. The KUKA PCD is thus compatible with Industrie 4.0 and ensures greater productivity, traceable quality and data transparency. 

The unique KUKA PCD assures:

  • 100% reproducibility
  • 100% quality monitoring in real time 
  • 100% process reliability (minimization of rejects)
  • 100% documentation of the welding process

KUKA PCD: process parameter control and monitoring