Coldwater Machine Company is demonstrating its SpotMeldTM system capabilities at FABTECH 2015 in booth #S2158. SpotMeld is a Refill Friction Stir Spot Weld (RFSSW) solution that enables spot welding of aluminum (1000 – 7000 series), magnesium, non-ferrous and dissimilar sheet materials, offering an alternative to single-point joining processes like resistance spot welding, laser welding and riveting.
The SpotMeld system uses rotational friction to heat the materials along with pressure to forge together the parts using wear-resistant tooling to join two or more surfaces. Heat is generated between the tool and material, creating a soft region. Pressure is then applied, resulting in a solid state joint. Benefits of include the ability to join flexible sheet thickness combinations in one operation with a high quality joint that is near original material strength, a small heat affected zone, consistency in weld duplication and faster weld times, as well as being environmentally cleaner and safer with no filler material, spatter, smoke, radiation or shield gasses.
Coldwater Machine’s SpotMeld friction stir spot welders can be configured to application specifics and mounted on any industrial robot. A variety of weld recipes can be used on demand by the robot controller, which results in a very flexible production system.
SpotMeld Process Summary
Coldwater Machine Company will highlight the capabilities of its SpinMeldTM friction spin welding system at FABTECH 2015 in booth #S2158. SpinMeld systems reduce cycle times and defects as compared to traditional welding or joining techniques. Additionally, SpinMeld technology can join steels, aluminum, cast or sintered metals, magnesium, brass, carbon fiber composites, ceramics with mixed metal connections, and dissimilar combinations of these materials. Shafts, valve bodies, pistons, brackets and airbag inflators are just some of the components well-suited for SpinMeld production. Coldwater also offers SpinMeld production services for short run and prototype parts.
SpinMeld systems rely on rotational friction welding principles and a direct drive approach where a spinning workpiece, driven at a constant speed by an electric motor, is joined to a stationary one by rotational friction and externally applied force. It’s an extremely fast process that that produces frictional heat at a sufficient temperature for the materials to reach a plastic state (non-melting or Solid State) at the joint interface. The materials are then forged together by force.
SpinMeld solutions offer numerous benefits, including higher quality joints with high hardness, a very small heat affected area, and no coarse grain formation. The systems are also extremely energy efficient as 95 percent of the mechanical energy is transferred into heat. SpinMeld is also environmentally friendly, eliminating the need for filler metals, fluxes or shielding gases.
The SpinMeld systems are available as stand-alone vertical or horizontal machines that can be integrated into a work cell or an automated processing line. Each system is designed to fit the individual application with machine parameters such as rotational speeds, cycle times, and forging forces based on the material composition, part configuration and contact surface area of each joint. Rotational speeds are available from 2,000 to 23,000 rpm and forging forces from 335 to 12,000 lbf. The systems can be designed with a maximum weld area of 0.992 in2 (640 mm2).
Production quality samples for evaluation and testing using your work pieces can be created within our joining center to prove process feasibility.
SpinMeld Process in Action
Our core business over the years has evolved from precision machining to providing dies, fixtures, and gages, and to providing turnkey automated systems for the Aerospace, Appliance and Automotive industries that include a wide range of flexible and agile metal forming and fabricating solutions.