RIFTEC presents FSW solutions for railway vehicle construction at the Friction Welding Symposium

Dr. Thomas Luhn presented innovative applications of friction stir welding (FSW) technology for rail vehicle construction at the Friction Welding Symposium of the h² University of Applied Sciences in Magdeburg on march 18th, 2025. The focus was on the production of a headstock - a safety-critical structural component - made from thick-walled aluminium alloys.

Technical highlights of the project:

Large-format assembly: 3,070 x 1,580 x 492 mm,  total weight 1,525 kg

Material combination: Extruded profiles and forged parts made from EN AW-6005A T6 and EN AW-6082 T6

High-strength welded joints: 14 welding seams with a penetration depth of up to 27 mm

Quality assurance: Extensive tests in accordance with DIN EN ISO 15085 and DIN EN ISO 25239

By using friction stir welding it was possible to minimise distortion, achieve precise tolerances and a high mechanical load-bearing capacity. Friction stir welding offers advantages in terms of reduced process steps and improved quality assurance, particularly in comparison to conventional processes such as MIG welding.

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With over 22 years of experience in industrial FSW applications RIFTEC is leader in manufacturing high-quality components for the railway, automotive and aerospace industries.

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