Innovative ODFSW Technology for Energy Efficiency and Green Policy Compliance in Manufacturing

¹ Mechanical Engineering Department, Faculty of Engineering, Universitas Sebelas Maret, Surakarta, Indonesia
² Research Center for Manufacturing Technology of Production Machinery, National Research and Innovation Agency (BRIN), South Tangerang, Indonesia

^* Corresponding author: nurulmuhayat@staff.uns.ac.id

Abstract

The application of innovative welding technology is essential in modern manufacturing to address challenges related to energy efficiency and compliance with environmental policies. One-Step Double-Acting Friction Stir Welding (ODFSW) is an advancement in solid-state welding specifically designed to join thick components made of lightweight alloys without melting the base material. Unlike conventional fusion welding, which often causes high thermal distortion and porosity, and heavily relies on operator skill. ODFSW operates below the melting point using two tools that simultaneously operate from the top and bottom sides in a one-step process. This technology offers several advantages, including deeper penetration, lower heat input, shorter times, and reduced need for workpiece flipping. Consequently, ODFSW produces energy-efficient, defect-minimized, and environmentally friendly joints compared to conventional methods. Furthermore, through the implementation of semi-automatic welding systems, ODFSW effectively supports the concepts of smart manufacturing, automation, and environmental sustainability. With its ability to reduce energy consumption and carbon emissions while meeting green policy standards, ODFSW presents an ideal solution to sustainable manufacturing practices. This innovation not only improves the quality and productivity of metal joints but also contributes to supporting industrial transformation for enhanced energy efficiency and compliance with global environmental regulations.