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High-Performance Weld Joints
Structural and pressure-containing joints in aluminum weldments.
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Industrial Machinery
LeapFast provides friction stir welding as a service to machinery builders: leak-tight, high-strength joints in aluminum and dissimilar metals, produced without filler, shielding gas, or post-weld straightening.
Aluminum weldmentsAluminum-to-copper jointsHigh-vacuum equipment
Primary capability
Friction Stir Welding (FSW)
Friction stir welding joins metal below its melting point. The result is a wrought, fine-grained joint substantially stronger than an arc weld, with minimal distortion and none of the porosity or hot cracking that come with a melt pool. It also joins metals that cannot be fusion welded at all, freeing a designer to pick the best alloy for the job rather than the most weldable one.
The problem
If Any of These Is True, It Is Worth a Conversation.
01Leak-test failures and scrap eroding margin on a welded assembly
02Distortion and cracking creating rework and post-processing
03Excessive machining content driving piece price up
04Multi-step assembly: joint prep, braze foil, fit-up, furnace
05Alloy selection being driven by weldability rather than performance
06Weight carried in fasteners, tubes, and brazed joints you would rather not have
Applications
What We Build for Industrial Machinery
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Dissimilar-Metal Joints
Aluminum-to-copper and bimetallic transitions that replace bolted or brazed assemblies.
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Unweldable Alloys
High-strength series that crack under fusion welding are routine for FSW.
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High-Vacuum & Food/Medical
Hermetic joints for vacuum-tight and process-grade equipment.
Also available
Beyond the Primary Capability
Leapsight & MetalWorks Digital Twins
We model and optimize weld parameters before cutting metal, which shortens the path to qualification and holds quality once you are in production.
Why us
What Stands Behind the Claim
- Stronger Joints
- Substantially stronger than arc welding, with minimal distortion and no filler or shielding gas.
- Hermetic Seal
- Not reliably achievable with mechanical or brazed joints.
- AWS D17.3
- LeapFast qualifies friction stir welding procedures to AWS D17.3 and to NASA specifications.
- Brochure
- Download the FSW one-sheet (PDF)
Questions
Straight Answers
Can You Handle Production Volume?
Capacity scales through our equipment and university partners, we can rent or procure equipment as a program grows. We will show you the ramp plan before you commit to anything.
Our Current Design Works Fine. Why Change?
Then we are probably not a fit for that part. It gets interesting where there are leak-test failures, machining hours, or a performance ceiling.
Next step
Send Us the Part That Is Holding Up Your Program.
A drawing, a STEP file, or a sketch and a size is enough. We reply within 3 business days, including when the answer is no.
contact@leapfast.com
(330) 242-6951
252 W Boardman St, Youngstown, OH 44503