Manufacturing Technology, Inc.

Friction Welding

Table of ContentsIntroduction to Friction Welding 2

Advantages of MTI’s Process 3

Inertia Friction Welding 4

Direct Drive & HybridFriction Welding 5

Machine Monitors & Controllers 6

Safety Features 7

Flash Removal 7

MTI Welding Services 8

Weldable Combinations 9

ApplicationsAircraft/Aerospace 10Oil Field Pieces 14Military 16Bimetallic & Special 20Agricultural & Trucking 22Automotive 28General 38

Special Welders& Automated Machines 46

Machine Models & Capabilities 48

All of us at MTI…

would like to extend our thanks for your interest

in our company. Manufacturing Technology, Inc.

has been a leading manufacturer of inertia, direct

drive and hybrid friction welders since 1976.

We hope that the following pages will further

spark your interest by detailing a number of our

products, services and capabilities.

We at MTI share a common goal…to help you

solve your manufacturing problems in the most

efficient way possible. Combining friction welding

with custom designed automation, we have

demonstrated dramatic savings in labor and

material with no sacrifice to quality. Contact us

today to find out what we can do for you.

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n4Friction Welding

What It IsFriction welding is a solid-state joining process that produces

coalescence in materials, using the heat developed between surfacesthrough a combination of mechanically induced rubbing motion andapplied load. The resulting joint is of forged quality. Under normalconditions, the faying surfaces do not melt. Filler metal, flux andshielding gas are not required with this process.

Dissimilar MaterialsEven metal combinations not normally considered compatible can

be joined by friction welding, such as aluminum to steel, copper toaluminum, titanium to copper and nickel alloys to steel. As a rule, allmetallic engineering materials which are forgeable can be frictionwelded, including automotive valve alloys, maraging steel, tool steel,alloy steels and tantalum. In addition, many castings, powder metalsand metal matrix composites are weldable.

Savings—Cost, Time, MaterialSince dissimilar materials can be joined, a significant cost savings is

possible because engineers can design bimetallic parts that useexpensive materials only where needed. Expensive forgings and castingscan be replaced with less expensive forgings welded to bar stock, tubes,plates and the like.

Substantial time savings are realized since the process is significantlyfaster than more conventional methods of welding.

ManufacturingTechnology, Inc.(MTI) was founded in 1976 as acompany specializing in frictionwelding. At that time, MTI acquired allavailable patents, technicalspecifications, and productdevelopment information fromCaterpillar Tractor Company for InertiaWelders and AMF’s Flywheel FrictionWelders. A further addition was made in1985 when MTI acquired the rights toNew Britain’s line of Direct Drive FrictionWelders. Today, MTI offers a completeline of Inertia, Direct Drive, and HybridDirect Drive Friction Welders.

With machines in use around theglobe, MTI is a world leader indesigning and building inertia anddirect drive friction welders by helpingmajor industries solve many of theirmost complex manufacturing problems.Applications typically friction weldedinclude aircraft and aerospacecomponents, cutting tools, agriculturalmachinery, automotive parts, oil fieldpieces, waste canisters, militaryequipment, spindle blanks andbimetallic materials.

We continue to expand ourknowledge, equipment size andvolume, while adding complementarytechnologies to our product line, andmaintaining contract welding servicesfor industries with variable or lowvolume needs.

Friction weldingproduces forged quality

joints, with a 100%butt joint weld through

the contact area. Thissolid section shows the

narrow heat-affectedweld zone and resulting

displaced material(flash).

Transition jointfor cryogenic

application.Inconel to

aluminum.

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n5

Automated 60B InertiaFriction Welder (shownbelow with guardingremoved) used to weldautomotive air conditioningcomponents (left).

Metal combinationsnot normallyconsidered“weldable,” such asthese copper toaluminum electricalconnectors, can bejoined in frictionwelding.

Advantagesof MTI’sWeldingProcessTop Ten Reasonsto ConsiderFriction Welding1. Dissimilar metals are joined,

even some consideredincompatible or unweldable.

2. The process is at least twice—and up to 100 times—as fast asother welding techniques.

3. Friction welders are versatileenough to join a wide range ofpart shapes, materials and sizes.

4. Joint preparation isn’t critical…machined, saw cut, and evensheared surfaces are weldable.

5. Resulting joints are of forgedquality, with a 100% butt jointweld through the contact area.

6. The machine-controlled processeliminates human error, andweld quality is independent ofoperator skill.

7. It’s ecologically clean—noobjectionable smoke, fumes, orgases are generated that needto be exhausted.

8. No consumables are required—no flux, filler material, orshielding gases.

9. Power requirements are as lowas 20% of that required ofconventional welding processes.

10.Since there is no melting, nosolidification defects occur, e.g.gas porosity, segregation or slaginclusions.

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n6Inertia

FrictionWelding

Inertia Friction Welding is avariation of friction welding inwhich the energy required tomake the weld is supplied primarilyby the stored rotational kineticenergy of the welding machine.

In Inertia Welding, one of theworkpieces is connected to aflywheel and the other isrestrained from rotating. Theflywheel is accelerated to apredetermined rotational speed,storing the required energy. Thedrive motor is disengaged andworkpieces are forced together bythe friction welding force. Thiscauses the faying surfaces to rubtogether under pressure. Thekinetic energy stored in therotating flywheel is dissipated asheat through friction at the weldinterface as the flywheel speeddecreases. An increase in frictionwelding force may be applied(forge force) before rotation stops.The forge force is maintained for apredetermined time after rotationceases. The relationship betweenthe Inertia Friction Weldingparameter characteristics appearsin the diagram.

Induced failure showinghelical flow on an Inertia

Friction Weld.

AdvantagesInertia Friction Welding has

several advantages over theDirect Drive Friction Weldingprocess:• Narrower heat affected

zones.• Shorter weld times.• Helical flow lines and hot

working at end of weld cyclecan help in weld strength.

• Ease of monitoring, given onlytwo variables for welding:energy (RPM) and pressure.Energy can be monitoredbefore signal is given to weldreducing the variables during

welding to one.• Pre-calculable parameters for

most materials and geometry.The process can, therefore, bemathematically scaled (i.e.small samples can be used forlarge parts development).

• No clutches, no brakes.• Weld torque is measured

indirectly by measuring therate of spindle speed change.

• Meets Military Standard 1252and welding specifications ofnumerous large corporationsin the U.S.A.

• Largest Inertia Friction Welderhas 2250 ton forge force.

The relationship ofinertia friction

welding parametercharacteristics.

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n7Direct Drive

& HybridFrictionWelding

Direct Drive Friction Welding is a variationof friction welding in which the energyrequired to make the weld is supplied by thewelding machine through a direct motorconnection for a preset period of the weldingcycle.

In Direct Drive Friction Welding, one of theworkpieces is attached to a motor-driven unitwhile the other is restrained from rotation. Themotor-driven workpiece is rotated at apredetermined constant speed. The workpiecesto be welded are forced together and then afriction welding force is applied. Heat is generatedas the faying surfaces (weld interfaces) rubtogether. This continues for a predeterminedtime, or until a preset amount of axial shortening(upset) takes place. The rotational driving force isdiscontinued and the rotating workpiece isstopped by the application of a braking force orby the weld itself (Inertia Welding). The frictionwelding force is maintained, or increased, for apredetermined time after rotation ceases (forgeforce). The relationship between the Direct DriveFriction Welding parameter characteristics isshown in the diagram.

MTI’s Hybrid Direct Drive Friction Welders useAC or DC variable speed drives that eliminateclutches and brakes. Proportional hydrauliccontrols guarantee smooth up and down forcecontrol. Through manipulation of decelerationtimes and forge force ramp up time, welds can bemade ranging from near Inertia Friction welds toclassic Direct Drive Friction welds.

Induced failureshowing typical classicDirect Drive FrictionWeld flow pattern.

AdvantagesThe Direct Drive Friction Welding process has

several advantages over Inertia Friction Welding:• Lower weld force for solid parts. Larger parts can be

welded on same tonnage machine.• Lower weld torque if brake is applied at end of weld

cycle. Tooling requirements are, therefore, less rigid.• Lower RPM for solid parts.• Weld direct to finished length of ±.015 in. (±.38 mm)

or better with parts that have a larger tolerancebefore welding (i.e. ±.050 in. [±1.27 mm]).

• Angular orientation after welding of ±1° or better ispossible between the two pieces.

• No flywheel change between setups.Weld quality should never be sacrificed to obtain

dimensional accuracy or angular orientation.

The relationship ofdirect-drive frictionwelding parametercharacteristics.

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n9Flash

RemovalThe flash curl generated

during welding is coherent,will not flake off, and canoften be left intact if designand engineeringconsiderations allow.Alternately, parts canfrequently be designed toaccommodate the flash curl ina recess (flash trap).

In many cases, if the weldflash must be removed, thiscan be accomplished on thewelder as an integrated part of themachine cycle. Part geometry andaccessibility of the flash are the twomajor factors which determinewhether on-machine flash removalcan be incorporated, and whichsystem can be employed.

Available systems include:• Shearing–outside• Shearing–inside• Plunge Cut–one axis• Plunge Cut–two axis

The customer must determine ifthe increase in machine cycle timeand additional complexity of themachine are warranted.

Above left: Model 120Inertia Welder equippedwith O.D. flash shearing.

Above right: Model 150BInertia Welder equippedwith plunge-cut flashremoval.

Right: Examples of I.D.and O.D. flash removedby shearing.

Safety FeaturesNew machines feature custom-designed

guarding with front sliding door for manualloading and unloading of parts, andremovable, stationary guards for rear andsides.

Physical interlocks are placed on thesliding door and all removable guarding.Program interlocks protect personnel and themachine by requiring certain conditions tobe met before allowing machine movement.

These same safety features can be addedto older machines during rebuild or retrofit.

Sound enclosures are available to softenthe sound decibels of the motors. Theyrange from an enclosure mounted directlyon the hydraulic unit (on smaller machines),to a complete room built around thehydraulic unit on very large machines.

Below: Model 120BInertia Friction Welderwith safety guardinginstalled.

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n10MTI

WeldingServicesResearch &Developmentand ContractJob Shop

MTI provides contract weldingservices for industries with variableor low volume needs. Our in-housejob shop offers both research &development, and productionservices. A wide range of inertia ordirect drive friction welders areavailable to accommodate customerapplications.

MTI’s knowledge, weldingcapacity, geographic location andproximity to heat treat sourcescombine to provide you with thebest value for your dollar.

• Machines are available forproduction runs for material sizesranging from .250 in. diameter to 6in. diameter solid, or 43 in.2 tubularsteel; with weld force ranging from6-ton to 450-ton.

• Current production lotquantities range from <5 to>300,000 pieces per year.

• Pre- and post-weld processingis available.

• Tooling available for most partconfigurations. Design capability forboth tooling and parts byexperienced Design EngineeringDepartment.

• Weld development, feasibilitystudies and metallurgical evaluationof weld quality performed byexperienced Metallurgist.

• Computer storage ofparameter data is available forcritical applications.

Model 400S Inertia Friction Welder

This 450 ton welder is the largest contract services welder used in the U.S.Typical applications welded on this 400S include large tubular steel parts,such as diesel engine pistons and aircraft components.

MTI Contract Job Shop.

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n11Weldable Combinations

in Friction WeldingSince dissimilar metals can often be joined, a significant cost savings can be realized by designing

bimetallic parts that use a minimum of expensive metals only where needed. Expensive forgings andcastings can sometimes be replaced with less expensive forgings welded to bar stock, tubes, and plates, orwith components created solely by welding together bar stock, tubes, and plates.

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Magnesium AlloysMolybdenum

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Silver AlloysSteel – Alloys

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Zirconium Alloys

Track roller carrier bracket. Weldedstructural shapes replace steel casting.Cost reduced by 25%, fatigue strengthimproved 7 1/2 times.

12

Aircraft/Aerospace

The demand for larger aircraftmeans that aero-engines are growingin thrust, temperature, and size. Towithstand the higher temperatures,critical aircraft and aerospacecomponents are being made withmaterials such as superalloy,bimetallic, stainless steel andaluminum. These materials, whichcan be difficult and many timesimpossible to weld with conventionalmethods, can be joined with thefriction welding process. Thesehigher-temperature materials, alongwith the large component size,require large amounts of weld energyand load. In order to meet thisincreasing demand, MTI designed a2,000 ton inertia friction welder. Thisis the largest friction welder madetoday. In addition to these largemachines, friction welders of all sizesare used in this industry. Aircraft/aerospace components frictionwelded include compressor rotors,fan shafts, cluster gears, landing gearcomponents, bimetallic rivets andhook bolts, aluminum heat pipes,and cryogenic rocket components. Aspecial machine was designed andbuilt to weld injector posts in the U.S.space shuttle main engines.

A Cluster gear cross section.

B Cluster gear.

C Inconel 718 tube to rotorassembly.

D Low compression titaniumrotor assembly.

E Jet engine compressor rotor–as welded.

F Fan blade rotor.

C

D

F

E

A

B

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s – Aircraft/A

erospace

G Landing gear drag brace.

H Landing gear component.

I Forged 300M clevis welded to 300Mtubing for manufacture of ball screw.Actuates swing wing on F-14 Fighter.

J Jet engine component–as machined.

K Extension welded to four-blade propellerhub forging.

L Bosses welded to accumulator housing –AISI4340.

K

L

I

J

H

G

14

D

AB

CA Military jet engine compensating

shaft–as welded.

B Fan shaft for military jet engine-Inconel.

C Commercial jet engine fan shaft–as welded.

D Military jet engine fan shaft,cross-section–as machined.

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s – Aircraft/A

erospace

G

I

H Stator vane adjustor lever-titanium.

I Aircraft hook bolts-superalloy.

J Lightweight piston foraircraft pump–17-4PH.

K Aluminum heat pipe foraerospace.

F

J K

E

H

E Left: Stator vane root weld-as machined.Center: with flash removed. Right: Statorvane root weld (titanium)–as welded.

F Ball screw actuator–alloy steel.

G Bimetallic aircraft rivets-titanium.

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C

Oil FieldPieces

Weld integrity is a must inthe oil field drilling industry.Proven reliability of frictionwelded connections, coupledwith the process advantagessuch as being clean, fast,consistent, and free ofoperator-induced error, makesfriction welding one of theleading methods of joiningflanges to valve bodies, drillpipe, high-pressure hosecouplings, and manifold tubes.

A typical string of drill pipecan be three to four miles long,composed of 30-foot sections.The friction welds support thelower drill stem assembly(made up of other drill pipes,drill collars and the drilling bit)and transmit the rotary torqueneeded for drilling. Frictionwelding produces ametallurgical bond strongenough to take the high torqueand highly loaded rotarytension due to directionaldrilling.

A Butterfly valves. Wrought stainless steel extension welded to investmentcast stainless steel butterfly valve.

B High-pressure valve body. Forged flanges welded to forged valve body.

C Cross-section of high-pressure valve body weld.

A

B

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D Geological core drill. SAE4140 end blankwelded to SAE4140 tubing.

E Sucker rod. Threaded end connector toforged sucker rod.

F Oil well drill pipe. Close-up of tooljoint todrill pipe weld. Female end.

G Oil well drill pipe. Close-up of tooljoint todrill pipe weld. Male end.

H Cross-section of Inertia Welded manifoldtubing used on oil well heads.

G

F

E

H

Ap

plicatio

ns – O

il Field Pieces

D

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MilitaryGovernment agencies in the

United States and abroad relyon MTI as their friction weldingtechnology source. MTI’scontinued research into thestored energy approach tofriction welding, first pioneeredby Caterpillar Tractor, Inc. andAMF, resulted in the first militarystandards written around theinertia welding process (MIL-STD-1252).

The advantages of thisprocess such as no smoke,fumes or gases, or few sparksproduced, and the fact that theprocess is machine-controlled,make it suitable for use inpotentially explosive orhazardous environments. Themachine can be fullyautomated so the operator canbe safely located out of harm’sway. MTI’s machines andcontract welding services havebeen used in military defense,aircraft, aerospace and groundtransportation components.

A Formed cap welded to tubingfor manufacture of bomblet.

B Fuze liner.

C Fuze liners. Drawn thin-walltubing to heavy-wall tubingrings.

D Experimental machine gunbarrel liner.

E Closure for smoke mortar fillhole, aluminum.

D

E

A

B

C

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F Experimental windscreens toprojectiles.

G Torque tubes for amphibiouspersonnel carrier drive shaft.

H Front bomb case assembly.18 in. (457mm) O.D.

I Midcase bomb assembly.18 in. (457mm) O.D., 43 in.2

(27,740mm2) of weld area.

F

G

I

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ilitary

H

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A High-explosive bombdevelopment sample.

2 Mortar round.

C Copper alloy band to 30 mmsteel body.

D Adjusting link for trackedvehicle. AISI4140.

DC

A

FPO

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s – Military

E Impact wrench extensions.

F Copper alloy rotating band radiallywelded to 155 mm alloy steelprojectile body and cross-section.

G Experimental aluminum smokemortar.

F

E

G

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Bimetallic& SpecialApplications

Metal combinations notnormally considered compatibleare joined by friction welding,such as aluminum to steel,copper to aluminum, titanium tocopper, and nickel alloys to steel.Since dissimilar materials can bejoined, a significant cost savingsis possible by designingbimetallic parts that useexpensive materials only whereneeded. Engine valve headsmade from a nickel-chrome alloyfor heat resistance can bewelded to an alloy steel stem forwear resistance. A carbon steelshaft welded to a stainless steelstub provides corrosionresistance in pump motors.

MTI has experience with manybimetallic applications. Someothers include: copper toaluminum electrical connectors,aluminum to stainless steelcopier fuser rollers, titanium tocopper electrodes used inseawater desalinization cells, andstainless to alloy steel propellershafts for outboard motors.

A Carbon steel/stainless steel marineoutboard engine drive shaft

B Bimetallic pump motor shaft. Stainlesssteel stub joined to carbon steel shaftfor corrosion resistance.

C Inertia-welded copper-to-aluminumtensile specimen.

D Aluminum and copper electricalconnector.

A

B

C

D

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s – Bimetallic &

Special Applications

E Examples of various aluminum/copper electricalconnectors and a threaded titanium/copperelectrode stud.

F Aluminum/stainless copier fuser roller.

G Pin heading done using “interrupted” weld cycle.

H Solid 2219 aluminum/304 stainless steel tube.

I Transition joint for cryogenic application. Inconelto aluminum.

E

G

F

H

I

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Agricultural& Trucking

Friction welding is usedextensively in the agricultural andtrucking industries because thewelds are of forged quality, with a100% butt joint weld throughoutthe contact area. This bond isstrong enough to handle the highstress and torque required ofheavy machinery components.Component costs can besignificantly reduced by replacingexpensive, totally-forged partswith forged ends welded to bar ortube stock, without a reduction inquality.

One example of this would behydraulic piston rods, which havesimilar-size ends, but vary in roddiameter and length. Instead ofstocking expensive forgedcomponents in a variety ofdifferent diameter and lengthconfigurations, standardized endscould be welded to the required-size rod, reducing componentcosts as well as physical inventoryrequirements.

Other agricultural and truckingapplications include front axleyoke shafts, rear axles, driveshafts, and gears.

A Water pump gear.

B Cross-section of inertiawelded diesel engineprecombustionchamber–SAE5120.

C Water pump–aswelded.

D Water pump–finished.

E Diesel engine piston.

3

D

2

E

A

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s – Agricultural &

TruckingF Track roller. Forged halves welded together to produce track roller

assemblies.

G Steel-backed, bronze-laminate thrust washers and sleeves welded togetherto produce track roller bushings. Replaced costly solid bronze castings.

H 4 in. (101.6 mm) diameter bar stock welded to hub forging to produce rearaxles for tractors.

I Truck trailer brake S-cam.

J Forged wheel spindles joined to 5 in. (127 mm) diameter, .5 in. (12.7 mm)wall tubing to produce trailer axles.

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G

H I

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A Power control drive shaft formotorgrader. Inertia weldmentreplaces upset forging (left) whichrequired five straightening operations.

B Universal joint clevis.

C Front axle yoke shaft for four-wheel-drive vehicles. SAE1040 bar stock toSAE 1040 yoke forging.

D Pin assembly. Pre-chromed pinwelded to retaining plate.

B

C

D

A

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s – Agricultural &

Trucking

E Finished gear welded to clutch drum.

6 Oil pump gears. Welded bar stock replaces forgedblanks. 15%–30% cost reduction (depending on sizeand usage).

7 Cluster gear. Small finished gear welded to largergear blank.

8 Two pre-finished transmission gears welded usingprecision piloted tooling.

9 Chain drive sprocket.

8 9

G

E

6

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A Lift screw. Rollthreaded stock cut tolength and welded toscrew machined ends.

B Lift link-ball socket.Forged couplingswelded to tubing andbar stock.

C Truck rear suspensionlink welded on twin150 Inertia Welder.Ends are oriented towithin ±1° of eachother.

D Torque rod. Forged eyewelded to various barstock lengths.

A

CB

D

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s – Agricultural &

Trucking

E Hydraulic piston rods. Rod eyes cut from heavy-walltubing welded to pre-chromed bar stock.

F Track adjusting yoke for commercial tracked vehicles.

G Hydraulic piston rod.

H Bar stock welded to clevis forging for manufacture oflarge (5 in. (127 mm) diameter and larger) piston rods.

H

F

G

E

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AutomotiveIn the United States, the

automotive industry has played adramatic role in the volume offriction welding applications andequipment in the ’90s andpossibly the history of theindustry.

Automotive friction weldingapplications include: stabilizerbars, engine valves, torqueconverter covers, drive shafts,gear blanks, steeringcomponents, water pumps,axles, camshafts, air conditioningaccumulators, U-joints, andmore.

Demand for automotiveairbag inflators has stimulatedthe increase in the number offiction welders manufactured forthe automotive industry sincethe 1980s. Advantages such asfull-penetration weld, as well asits narrow heat-affected zonehave made friction welding a keymethod for joining fully-loadedairbag inflators. Successfulmaterial combinations includealuminum, low carbon steel, andstainless steel alloys.

Airbag InflatorsA Driver side airbag inflator–

cross-section.

B Passenger side airbag.

C Hybrid passenger sideairbag inflator.

D Driver & passenger sideairbag inflators.

E Side-impact airbaginflators.

F Passenger side airbaginflator and cross-section(aluminum).

6

A

3

5

2

4

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s –Autom

otive

7 Aluminum wheel rim and cross-section.

8 Forgings can be welded to bar stock, tubes,plates and the like, as shown with these driveshafts.

9 Experimental aluminum suspension link.

J Experimental chassis component.

K Retainer–differential bearing blank cross-section (left). Bearing housing retainer fortransaxle (right).

L Transmission part.

7

LK

J

8

9

32

A Hollow engine valves forlightweight and liquid-cooledapplications.

B Flanged axle.

C Experimental hollow automotiverear axle. Tubing welded to hubforging and spline blank.Replaces solid forging for weightreduction.

D Bimetallic engine exhaust valvesshowing head and stemcomponents, as-welded valveand welded valve with flashremoved by shearing.

E Automatic transmission outputshaft. Stamped steel flangewelded to bar stock.

F Fan shaft bracket assembly. Barstock welded to plate replacesmachined forging.

G Rolled ring gear welded toflywheel stamping producesdistortion-free flywheel ring gear. G

E

F

C

B

A

D

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s –Autom

otive

H Alternator bracket. Bar stock welded to plate replaced forging.

I Viscous drive fan shaft couplings. Replace forgings.

J Starter pinion assembly. Sintered steel gear welded to sleeve.

K Automotive hydraulic jack. Fabricated from tubing and plate stock.

L Cross-section of hydraulic jack showing 2 tubular welds which weremade simultaneously to the base plate.

M Speed selector shaft. Mild steel yoke welded to SAE1045 shaftreplaced pinned assembly.

L

M

J

I

K

H

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A Constantvelocity joint.

B Stem pinion.

C Forged cam shaft blank welded to forged flange.

D Forged yoke welded to bar stock for manufacture of tilt-steering shaft.

E Universal joint assembly with welded extension shaft.

F Steering shaft welded to pre-assembled knuckle.

G Water pump hub and shaft.

AB

C

E

F

G

D

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s –Autom

otive

H Automotive axle tube

I Rear axle housing tube. Forged tube endwelded to tube stock.

J Automotive transmission component.Machined tubing welded to cold-formedend.

K Electric motor housing and shaft forautomotive cooling fan.

L Direct clutch drum and hub assemblyused in automatic transmissions. Mildsteel tubing welded to cold-formedclutch drum. Cross-section.

KJ

L

H

I

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A Torque converter cover.Three mounting nutswelded to cover formounting of flywheelring gear.

2 Torque converter pump.

3 Clevis.

4 Worm gear drive shaft.

5 Drive shaft.

1

2 3

4

5

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s –Autom

otive

F Front wheel drive shaft.

G Turbocharger.

H Transmission gear. Finishedspiral bevel gear welded totubular shaft.

9 Wheel spindle.

J Air conditioner accumulator.Aluminum housing.

K Transmission input shaft.

J

K

9

G

F

H

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A Brake caliper. Tubingjoined to formed caliper.

B Drive extension (internalspline one end).

C Front suspension struts

D Sport utility 4X4interconnecting shaft.

5 Stabilizer bars. Tubewelded to solid end.Cross-section.

3

5

4

1

2

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s –Autom

otive6 Input shaft for automotive transmission. Stamped hub to

machined bar stock.

7 Shock absorber base cup. Weld between threaded stud andbase cup firmly traps washer in place.

8 Bumper shocks. Tubing welded to stamping for impactabsorbing bumper mounts.

9 Air conditioner rotor assembly. Outer rotor pole is welded toinner rotor pole then this assembly is welded to pulley blank.

6

7

8

9

40

GeneralAs a rule of thumb, probably

all metallic engineeringmaterials which are forgeable,are weldable by the frictionwelding process.

Generally, the onlyrequirement of the componentdesign, is that one of the piecesto be welded must have anearly-symmetrical shapearound its axis of rotation.

The second part to be joinedcan be of any shape or form, aslong as the weld contact area isa “butt” design. Jointpreparation is not critical—machined, saw-cut, and evensheared surfaces are easilywelded.

Our continuing developmentof new prototype applicationsallows us to remain a leader inthe friction welding industry.Contact MTI today to see howfriction welding can work foryou.

Cutting ToolsA Tool steel to carbon steel drill bit.

B Twist drill blank. Welded blanks made from M10 toolsteel bodies and SAE4140 shanks.

C Countersinks. High-speed steel (M2, M42) headswelded to mild-steel (1020) shanks.

D Keyway and T-slot cutters. Welded blanks made fromAISI 6145 shanks and M4 tool steel heads.

B

D

C

A

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Waste CanistersA Overpack (2nd safety weld) closure for

waste canister–stainless steel.

B Cross-section of primary closure weldand overpack weld.

C Cross-section of primary closure weld.

D Primary closure for waste canister–stainless steel.

A

B

DC

Spindle BlanksWelded blanks replace

costly forgings formachine tool spindles.

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A Check valve fitting to stampedhousing for refrigeration unit.

B Medical X-ray target.

C Disc brake for fork lift truck.

D Center screw for automotive jack.

E Golf putters.

F Axle shaft for lawn & gardentractor.

A

B C

ED

F

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G .375 in. (9.5 mm) diameter stud welded to backing plate.

H Lift screw assembly. Acme threaded bar welded to clevisblock.

I Finished ball and mounting stud.

J Flywheel ring gear for outboard motor. Forged hub weldedto stamped and heat-treated ring gear.

K Forged eye welded to bar stock.

L Actuator arm for sewing machines.

G

H

I J

K

L

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A Composite driverblade.

B Mining bit.

C Miniature weldapplication.

D Light weighthydraulic piston.

E High voltagecontact. Cu-Crto W-Cu.

F Diesel enginecylinder.

E

DC

1

2

F

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G Shifter yoke and pin assembly for marine transmission.SAE1010 steel pin welded to formed yoke.

H Engine tilt quadrant shaft used in marine stern drive engine.SAE8650 alloy steel bar welded to 410 stainless steel replacedmore expensive all-stainless forgings.

I Torque bolt. Head shears off when tightened to the propertorque.

J Eyebolt. Standard forged eyes are welded to various lengthsof bar stock.

K High-pressure hydraulic hose coupling. Standard flanges andstubs welded to bent-to-order tubing. Reduced inventory,improved delivery. Lower piece shows result of 21,000 psi(144,790 kPa) pressure test. No weld failure.

L Various hand tools. Forged, cold headed and stintered headsand ends welded to barstock handles and extensions.

G

H

KJ

L

I

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A Ports welded to cylinder body used inautomotive steering assembly.

B Fabricated hydraulic cylinder. Tubingwelded to end cap. Parts welded tocylinder body–AISI4340.

C Printing press roller. Five-piece weldedassembly comprised of tubing, endcaps and journals.

4 Automotive lug wrench. Bar stockwelded to formed socket.

A

B

4

C

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E Aluminum copier roller.

F “Throw away” hydrauliccylinder. Four welds tocomplete assembly.

G Tubular drive shaft.

H Accumulator.

E

F

G

H

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Special Model V120 Inertia Friction Welder

Special Welders and Automated MachinesOur design engineers and machine tool builders are specialists

in the design and building of custom welders and automationequipment. These special welding cells dramatically increaseproduction rates over manual operation, while requiring minimaloperating personnel.

Special vertical 120 Inertia FrictionWelder has CNC table to positionspace shuttle main engines forwelding of injector posts. Superalloyinjector posts are welded to spaceshuttle main engine. 600 posts perengine, 3 engines per shuttle.

Automated 180BX Inertia Friction WelderUsed for welding copier fuser rollers.

This welding cell includesautomated spindle loading,

fixture loading andunloading, two conveyors

for end cap and tubehandling, and unloadchute for off-loading

welded parts. Cycle time is45 seconds per weldedassembly (two separatewelds, one at each end

of tube.)

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Model T120 Inertia Friction WelderUsed for welding automotive stabilizer bars.

This twin welder has twoindependent spindles and

fixtures to weld two solid endsto a hollow tube

simultaneously. This weldingcell includes automated spindle

and fixture loading, flashshearing, flash removal

conveyor, and part unloadingconveyor. Welded assembliesare ready for fabrication and

finishing. Production rates(dependent on tube diameter

and wall thickness) are250–300 welded assemblies

per hour.

Magnetic Impulse WeldingMTI has introduced a magnetic impulse

welder to compliment its line of frictionwelders. Magnetic impulse welding is a solidstate process that produces radial lap jointswith parent metal strength. Two workpiecesare placed in nonconductive locating devices,inside a continuous inductor. A bank ofcapacitors is charged to the desired level, andthen discharged producing an extremely highrate of energy transfer to the inductor. Therapid rise in magnetic flux inside the inductorresults in eddy currents on the surface of theouter workpiece. The eddy currents are thenrepelled by the inductor, resulting in acompressive radial force similar to thatproduced in explosive bonding. The outerworkpiece impacts the inner at a very highvelocity, resulting in a metallurgical bond.

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Direct Drive Machine Models & CapabilitiesDifferent combinations and modifications are possible. All machines can be equipped with automatic load and unloaddevices, flash removal, and quality control machine monitors. All weld speeds are variable from 0 to maximum.

Max. Solid Max. TubularRPM (Max.) Max. Forge Force Diameter Weld Area

Model Variable lb • kN in • mm in2 • mm2 Version

7.5T, FW 3,000 15,000 • 66.7 1.0 • 25.4 1.07 • 690 B, BX, D, T, V

10T, FW 3,000 20,000 • 89 1.13 • 28.7 1.43 • 923 B, BX, D, T, V

15T, FW 2,500 30,000 • 133 1.5 • 38 2.0 • 1 290 B, BX, D, T, V

30T, FW 2,000 60,000 • 267 1.9 • 48.3 4.2 • 2 768 B, BX, D, T, V

45T, FW 1,500 90,000 • 396 2.39 • 60.7 6.4 • 4 148 B, BX, T, V

60T, FW 1,300 120,000 • 533 2.9 • 74 8.0 • 5 161 B, BX, T, V

100T, FW 1,000 200,000 • 889.6 3.57 • 90.7 14.2 • 9 219 B, BX, T, V

125t, FW 1,000 250,000 • 1 112 4.0 • 101.6 17.8 • 11 523 B, BX, T

150T, FW 1,000 300,000 • 1 332 4.37 • 111 20.0 • 12 903 B, BX, T

175T, FW 1,000 350,000 • 1 556 4.7 • 119.4 23.5 • 15 161 B, BX

200T, FW 1,000 400,000 • 1 780 5.0 • 127 26.8 • 17 290 B, BX

Inertia Welder Machine Models & CapabilitiesDifferent combinations and modifications are possible. All machines can be equipped with automatic load and unloaddevices, flash removal, and quality control machine monitors. All weld speeds are variable from 0 to maximum.

Max. TubularRPM (Max.) Max. Flywheel Max. Weld Force Weld Area

Model Variable lb–ft2 • kg–M2 lb • kN in2 • mm2 Version

40 45,000/60,000 0.015 • 0.00063 500 • 2.22 .07 • 45.2 B, D, V

60 12,000/24,000 2.25 • 0.094 9000 • 40.03 .66 • 426 B, BX, D, V

90 12,000 5.0 • 0.21 13,000 • 57.82 1.0 • 645 B, BX, D, T, V

120 8,000 25 • 1.05 28,000 • 124.54 1.7 • 1 097 B, BX, D, T, V

150 8,000 50 • 2.11 50,000 • 222.4 2.6 • 1 677 B, BX, T, V

180 8,000 100 • 4.2 80,000 • 355.8 4.6 • 2 968 B, BX, T, V

220 6,000 600 • 25.3 130,000 • 578.2 6.5 • 4 194 B, BX, T, V

250 4,000 2,500 • 105.4 200,000 • 889.6 10 • 6 452 B, BX, T, V

300 3,000 5,000 • 210 250,000 • 1 112.0 12 • 7 742 B, BX, T, V

320 2,000 10,000 • 421 350,000 • 1 556.8 18 • 11 613 B, BX

400 2,000 25,000 • 1 054 600,000 • 2 668.8 30 • 19 355 B, BX

480 1,000 250,000 • 10 535 850,000 • 3 780.8 42 • 27 097 B, BX

750 1,000 500,000 • 21 070 1,500,000 • 6 672.0 75 • 48 387 B, BX

800 500 1,000,000 • 42 140 4,500,000 • 20 000 225 • 145 160 B, BX

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Model 200 Ton Direct Drive Friction WelderUsed to weld piston rods for large construction equipment.

B (Box Style) BX (Open Top)

T (Twin–2 Spindles)) D (Dual-Center Drive)

V (Vertical)

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Model 35 TON Direct Drive Friction WelderUsed to weld bearing housing retainer for transaxle.

Model 15 TON Direct Drive Friction WelderUsed to weld airbag components.

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Model 180 VerticalInertia Friction Welder

Used to weld airbag components.

Model 180B Inertia Friction Welder.Used to weld flywheel ring for outboard motor.

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Model 40B Inertia Friction WelderUsed to weld heat tubes for satellite applications.

Model 90B Inertia Friction WelderUsed to weld engine valves.

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Model 120B Inertia Friction WelderUsed to weld automotive air conditioning components.

Model 120B Inertia Friction WelderUsed to weld turbochargers.

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Model 60 TON Direct Drive Friction WelderUsed to weld axle tubes to forged flanges.

Model 45 TON Direct Drive Friction WelderUsed to weld stainless to carbon steel pump shafts.

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Model 250B Inertia Friction WelderUsed to weld diesel engine pistons.

Model 250BX Inertia Friction WelderUsed to weld valve bodies.

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Model 480B Inertia Friction WelderUsed to weld aircraft components.

Model 320BX Inertia Friction WelderUsed to weld oilfield drill pipe.

World’s Largest Friction WelderMTI builds the largest friction welders made today. The first of these

2,000-ton axial machines, built in 1991, was designed to weld aircraft enginealloys and components. MTI is the only manufacturer of large friction weldersover 300-ton capacity.

Model 800B Inertia Friction WelderUsed to weld jet engine components.

This brochure is ©1999 by Manufacturing Technology, Inc. (MTI). All rights reserved. This brochure is distributed by MTI forinformation purposes only. MTI provides the material “as is” without warranties of any kind, either express or implied. Duplicationof any part(s) without express written permission of MTI is strictly prohibited.

Manufacturing Technology, Inc.

1702 W. Washington Ave. • South Bend, IN 46628

574-233-9490 • Fax 574-233-9489

Email: info@mtiwelding.com

Website: www.mtiwelding.com