There have been pivotal moments throughout history when humanity introduced new technologies. It provides key advantages to those who have the vision to embrace them. Take the Automotive industry, for example: it shifted from steam power to internal combustion engines, and now electrification is emerging. Those who have recognized the potential of new technologies early on have been able to capitalize on increased productivity, improved performance, and sustainability.
That’s the idea behind our new Weld Development 2.0 package. In this new package, MTI tests the feasibility of your application with traditional friction welding as usual, plus we also perform Low Force friction welding test welds so you can compare the benefits of the new technology directly with the traditional friction welding processes.
Understanding the Traditional Weld Development
If you’re new to the idea of a Weld Development, or if you just need a quick refresher, we have a dedicated blog and a Whiteboard Wednesday episode to walk you through MTI’s process step by step. But here’s a quick recap:
The main purpose of weld development is to optimize results, ensuring that the production parts are fit for purpose by exceeding their in-service performance. This process includes testing your materials, geometries, part sizes, and more to validate that friction welding meets your requirements.
MTI’s Weld Development process happens in three phases:
- Phase 1 – Proof of Concept: In this first phase, our team leverages 100 years of engineering experience, combined with state-of-the-art modeling and calculations, to determine the optimal solution for your joining application. This phase will focus on the metallurgy and component geometry, but can also consider the commercial and manufacturing impact of the process. This work effort may also include welding simple material specimens, commonly referred to as coupon welds, to characterize the mechanical performance of the bond and to confirm calculations.
- Phase 2 – Small-Scale Development: In Phase 2, we develop small-scale samples of your part to test their post-weld performance and durability. These weld specimens may have the same geometry as the final part, but are small-scale. This phase is particularly useful when developing bonds between exotic or expensive materials, where we want to understand the material’s behavior during the welding process.
- Phase 3 – Full-Scale Development: In the final phase, we develop full-scale parts to test their viability on our range of laboratory and production friction welding machines. These components can be subject to real-world service testing or prototype validation. It eliminates potential technical risks associated with your component’s design before manufacturing production-ready parts or purchasing an MTI machine.
Traditionally, if friction welding is successful, we’ll start a conversation on whether you need a dedicated machine or contract services. When the appropriate friction welding process has been developed and successfully applied to your application, MTI can offer the design and manufacturing of a friction welding machine dedicated to your production needs. Alternatively, we can support your production with any of our in-house friction welding machines.
But here is where Low Force comes in.
Low Force Friction Welding
Though Low Force is our newest technology, it has already been adopted for multiple applications by those who have improved the process, observed the benefits, and capitalized on them to gain an industrial advantage. In fact, there are 13 Low Force friction welding machines operating in the industry today.
As we continue to optimize the Low Force process, we are seeing technical optimizations and advantages over traditional friction welding across multiple applications, including little to no flash formation, faster cycle times, superior mechanical performance, and improved overall part design. But the benefits don’t stop with your parts. Investing in Low Force can improve your entire manufacturing process.
Axle comparison showing traditional friction welding on the left side and Low Force friction welding on the right.
With in-machine post-weld heat treatment, little to no flash, customization of post-weld characteristics, and the ability to accommodate a wider range of parts, Low Force can eliminate entire steps from your manufacturing process. For example, in-machine heat treating may allow you to remove a secondary piece of heat-treating equipment from your production line.
Often, the flash produced by traditional friction welding must be removed from the components after welding. The Low Force process has a beneficial flash morphology resembling a small, smooth bulge, compared to the larger bifurcated flash curls, which can eliminate the need for flash removal in some applications. The Low Force welded component would be ready to move on to its next step, while a traditional friction-welded component would still be in process.
Now, let’s bring it all together.
The Processes in Weld Development 2.0
We want you to get the most out of your friction welding process, which is where our new Weld Development 2.0 package comes in. It’s a process meant to uncover potential improvements not only in your current welding process but also in your entire production line, including part design enhancements and the elimination of pre- or post-weld process steps. Now, you can test the feasibility of your application with traditional friction welding and Low Force side-by-side! You’re able to see the advantages of Low Force not just in the performance of your component, but also through your broader production line.
Our Weld Development 2.0 program will follow the same traditional phases, but with two technologies. Taking a closer look at Phases 1 and 2, you can expect side-by-side developments, tests, and results for both traditional and Low Force processes. Phases 1 and 2 will provide critical feasibility insight into your materials and part geometry with respect to the Low Force technology. MTI engineers will perform metallurgical tests, including mechanical performance testing, to ensure your part’s requirements are met.
As Phase 3 approaches, your team and MTI will work together to analyze the results of traditional and Low Force friction welding to decide the right path for your project.
Let’s Get Started
If you’re ready to discuss a weld development or if you have more questions, we’re ready to help! Reach out to any of our knowledgeable sales engineers to get a conversation started today. Or, feel free to learn at home, as we have multiple resources available for Low Force friction welding.
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