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CYTEC · CYSTIR Technology

(FSW) Friction Stir Welding

The CYSTIR motor spindle and the 2-axis welding head are specifically designed for friction stir welding to create a perfectly fused conjunction between similar and non-similar metals – achieving a perfect state of plasticity and a strong bond between different materials.

CYSTIR motor spindle – annotated cutaway with shear force transducer, torque motor, hybrid bearings and HSK tool interface

CYSTIR motor spindle designed specifically for friction stir welding.

Characteristics :

• HSK tool interface with hydromechanical Cytwist tool clamping system

• CyTorque motor (combinable with all common control systems)

• Pre-loaded CyRt hybrid bearing

• Shear force transducers to regulate forces during the welding process

• Rotary union for clamping and release hydraulics

CYSTIR 24 kW and 17 kW – technical drawings with dimensions and performance diagrams
CYSTIR 24 kW and 17 kW – dimensions, shear-force-transducer interface and performance diagrams

CYSTIR Variants – Technical Data

Three CYSTIR motor spindles cover the FSW application range – from the compact robotic head to the G30 forkhead with 40 kN axial load. Click a variant for its technical data:

Power (S1/S6)17 / 20 kW
Torque (S1/S6)40 / 48 Nm
Rated / max. speed4,000 / 9,000 rpm
Current (S1/S6)48 / 57 A
Max. axial / radial load15 kN / 5 kN
Tool interfaceE63 / A63
Clamping force / pressure22 kN / 55 bar
Clamping monitoringCyCon K11
Weight88 kg
Power (S1/S6)24 / 31 kW
Torque (S1/S6)56 / 73 Nm
Rated / max. speed4,050 / 5,000 rpm
Current (S1/S6)42 / 54 A
Max. axial / radial load15 kN / 5 kN
Tool interfaceHSK
Clamping force / pressure22 kN / 55 bar
Clamping monitoringCyCon K11
Weight95 kg
Power (S1/S6)42 / 53 kW
Torque400 Nm
Rated / max. speed1,000 / 7,000 rpm
Current200 A
Max. axial / radial load40 kN / 20 kN
Tool interfaceHSK-A100 (Ø125)
Clamping force / pressure40 kN / 75 bar
Weight350 kg
FSW friction stir welded cooling components
FSW welded plate – corner detail
FSW spindle welding a long aluminum plate
Stacked friction stir welded aluminum profiles
FSW machining of a round component
Robotic FSW welding of a curved aircraft panel
CYSTIR and CyWeld FSW system
Blue CNC Head and FSW tool with precision tip

Robust FSW fork head with 6-axis force sensors, high torque, compact design, and advanced cooling for precision welding.

Characteristics :
• HSK tool interface with hydromechanical Cytwist tool clamping system
• CyTorque motor (combinable with all common control systems)
• Pre-loaded hybrid bearing
• Shear force transducers to regulated forces during the welding process
• Rotary feedthrough for clamping and release hydraulics

Technical diagram of FSW Spindle mechanical component
CYSTIR Spindle Technical Overview

MOTOR SPECIFICATION

CYSTIR Motor Spindle Comparison
Specification CYSTIR 17 kW
Robotic Head 		CYSTIR 24 kW
Robotic Head / Forkhead 		CYSTIR 42 kW
Forkhead G30
Power (S1/S6) 17 / 20 kW 24 / 31 kW 42 / 53 kW
Torque (S1/S6) 40 / 48 Nm 56 / 73 Nm 400 Nm
Rated Speed 4,000 rpm 4,050 rpm 1,000 rpm
Max Speed 9,000 rpm 5,000 rpm 7,000 rpm
Current (S1/S6) 48 / 57 A 42 / 54 A 200 A

OPERATING DATA

Specification CYSTIR 17 kW CYSTIR 24 kW CYSTIR 42 kW
Max. Axial Load 15 kN 15 kN 40 kN
Max. Radial Load 5 kN 5 kN 20 kN
Weight 88 kg 95 kg 350 kg

CLAMPING SYSTEM

Specification CYSTIR 17 kW CYSTIR 24 kW CYSTIR 42 kW
Tool Interface E63 / A63 HSK HSK-A100 (Ø125)
Clamping Force 22 kN 22 kN 40 kN
Clamping Pressure 55 bar 55 bar 75 bar
Clamping Monitoring CyCon K11 CyCon K11 –

The Applications Friction Stir Welding

  • Aircraft Engineering

  • Space travel

  • Defense

  • Aircraft industry

  • Automotive industry

  • Fuel tanks

  • Atomizer

  • Aggregate

  • Coil joining

  • Connection of deck plates

  • …and many other production parts in different markets