Die-casting has been the go-to process for metal parts in serialized production for many years. In fact, die-cast parts are indispensable in almost all engineering industries.

If subsequent processes require these parts to be joined, however, the outcome is often less than satisfactory. Die-casting traps minute gas bubbles in the material – a circumstance that cannot be completely avoided. These pores expand in processes that involve heat. Thus, in conventional welding, porosity and subpar tightness are frequently an issue.

In contrast to conventional fusion welding, friction stir welding joins workpieces by stirring the components together along the joint line and forming welds under high pressure. As such, process temperatures remain relatively low compared to conventional joining techniques. The outcome: weld joints with excellent properties and density – even for die-cast components.

The automotive industry in particular has benefited from this innovative joining technique when forging friction stir welds with die-cast aluminum parts.

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