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The design, construction and use of a purpose-built friction stir welding machine for the welding of 15.9 mm (0.625 in) thickness, 1.88 m (74 in) long aluminium alloy 6061-T6 plate and extruded sections to form the side panels of a laser system is described. Off-the-shelf components were used where possible, with emphasis on strength and rigidity rather than machine tool precision. A variable speed tool drive is fitted, the work being held using a manually indexed vacuum table. The costs of this process were determined to be less than alternative welding methods and casting.

2nd International Symposium, 26-28 Jun 2000, Session 3, Paper 03