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Friction welding solutions for the Automotive industry

From our early days working for Studebaker Automotive to today, our extensive experience in automotive welding solutions is evident in the enormous variety of parts our machines produce. Those applications include stabilizer bars, engine valves, pistons, drive shafts, transmission gears, turbochargers, bumper shocks, suspension components, steering components, water pumps, axles, air bag inflators, camshafts, U-joints, and so many more. Friction welding may be fully integrated into automated production lines to handle this industry’s high volume demands.

How is MTI solving current problems in the automotive manufacturing industry?

We’re excited to share with you a NEW technical white paper about the advantages of friction welding in the automotive industry. In recent years, the automotive industry has faced an increasing number of challenges. Customers in the automotive industry demanded a machine that could keep product costs low, meet rigorous standards, and keep up with changing trends. Tier 1 and Tier 2 automotive suppliers were looking for a solution that could stand up to harsh environments but also help them achieve their lean manufacturing goals. Get started today and GO ALL IN!

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Sample Parts

Solution examples that make it easy to select the right
friction welding technology

Application	Section view of hybrid vehicle aluminum plate welded to cast aluminum heat exchanger box for a water tite seal. FSW weld path on plate is facing up.
Materials	Aluminum Alloys
Technology	Friction Stir Welding
Geometry	Lap

Application	Tailor welded blanks top view -1mm and 2mm thick aluminum sheets jointed prior to stamping. Used for vehicle lightweighting. Heavier 2mm material is deployed in crtical form support areas
Materials	Aluminum Alloys
Technology	Friction Stir Welding
Geometry	Lap

Application	Drive shaft sectioned part front view - tool exit hole shown -lightweighting vehicle while maintaining or increasing durability
Materials	Aluminum
Technology	Friction Stir Welding
Geometry	Lap

Application	Air conditioner rotor assembly. Outer rotor pole is welded to inner rotor pole then this assembly is welded to pulley blank.
Materials	Steel - Low Carbon
Technology	Rotary Friction Welding
Geometry	Tube to Disk

Application	Bumper shocks. Tubing welded to stamping for impact absorbing bumper mounts.
Materials	Steel - Low Carbon
Technology	Rotary Friction Welding
Geometry	Tube to Plate

Application	Shock absorber base cup. Weld between threaded stud and base cup firmly traps washer in place.
Materials	Steel - Low Carbon
Technology	Rotary Friction Welding
Geometry	Bar to Plate

Application	Input shaft for automotive transmission. Stamped hub to machined barstock.
Materials	N/A
Technology	Rotary Friction Welding
Geometry	Bar to Plate

Application	Figure 2 of 2 Welded stabilizer bar cross-section
Materials	Steel - Low Carbon, Steel - Medium Carbon
Technology	Rotary Friction Welding
Geometry	Tube to Bar

Application	Figure 1 of 2 Stabilizer bars. Tube welded to solid end.
Materials	Steel - Low Carbon, Steel - Medium Carbon
Technology	Rotary Friction Welding
Geometry	Tube to Bar

Application	Sport utility 4x4 interconnecting shaft
Materials	Steel - Low Carbon, Steel - Medium Carbon
Technology	Rotary Friction Welding
Geometry	Tube to Tube

Application	Front suspension struts
Materials	Steel - Low Carbon
Technology	Rotary Friction Welding
Geometry	Tube to Tube

Application	Drive extension (internal spline one end).
Materials	Steel - Low Carbon, Steel - Low Carbon Alloy (Gear Steel)
Technology	Rotary Friction Welding
Geometry	Tube to Tube

Application	Brake caliper. Tubing joined to formed caliper.
Materials	N/A
Technology	Rotary Friction Welding
Geometry	Tube to Disk

Application	Transmission input shaft
Materials	Steel - Low Carbon, Steel - Low Carbon Alloy (Gear Steel)
Technology	Rotary Friction Welding
Geometry	Bar to Plate

Application	Air conditioner accumulator. Aluminum housing.
Materials	Aluminum Alloys
Technology	Rotary Friction Welding
Geometry	Tube to Plate

Application	Wheel spindle
Materials	Steel - Low Carbon, Steel - Medium Carbon
Technology	Rotary Friction Welding
Geometry	Tube to Plate

Application	Transmission gear. Finished spiral bevel gear welded to tubular shaft.
Materials	Steel - Low Carbon Alloy (Gear Steel), Steel - Medium Carbon
Technology	Rotary Friction Welding
Geometry	Tube to Tube

Application	Turbocharger
Materials	Nickel-Based Heat Resistant, Steel - Medium Carbon
Technology	Rotary Friction Welding
Geometry	Tube to Disk

Application	Front wheel drive shaft
Materials	Steel - Medium Carbon
Technology	Rotary Friction Welding
Geometry	Bar to Bar

Application	Drive shaft
Materials	Steel - Low Carbon, Steel - Medium Carbon
Technology	Rotary Friction Welding
Geometry	Tube to Tube

Application	Worm gear drive shaft
Materials	Steel - Low Carbon, Steel - Medium Carbon
Technology	Rotary Friction Welding
Geometry	Bar to Bar

Application	Clevis
Materials
Technology
Geometry	Bar to Bar

Application	Torque converter pump
Materials	Steel - Low Carbon, Steel - Medium Carbon
Technology	Rotary Friction Welding
Geometry	Tube to Tube

Application	Torque converter cover. Three mounting nuts welded to cover for mounting of flywheel ring gear.
Materials	Steel - Low Carbon
Technology	Rotary Friction Welding
Geometry	Tube to Plate

Application	Figure 2 of 2 Direct clutch drum and hub assembly cross-section.
Materials	Steel - Low Carbon, Steel - Medium Carbon
Technology	Rotary Friction Welding
Geometry	Tube to Plate

Application	Figure 1 of 2 Direct clutch drum and hub assembly used in automatic transmissions. Mild steel tubing welded to cold-formed clutch drum. Cross-section.
Materials	Steel - Low Carbon, Steel - Medium Carbon
Technology	Rotary Friction Welding
Geometry	Tube to Disk

Application	Electric motor housing and shaft for automotive cooling fan.
Materials	Steel - Low Carbon, Steel - Medium Carbon
Technology	Rotary Friction Welding
Geometry	Tube to Disk

Application	Automotive transmission component. Machined tubing welded to cold-formed end.
Materials	Steel - Low Carbon
Technology	Rotary Friction Welding
Geometry	Tube to Plate

Application	Rear axle housing tube. Forged tube end welded to tube stock.
Materials	Steel - Low Carbon, Steel - Medium Carbon
Technology	Rotary Friction Welding
Geometry	Tube to Tube

Application	Automotive axle tube
Materials	Steel - Low Carbon, Steel - Medium Carbon
Technology	Rotary Friction Welding
Geometry	Tube to Bar

Application	Water pump hub and shaft
Materials
Technology	Rotary Friction Welding
Geometry	Bar to Plate

Application	Steering shaft welded to pre-assembled knuckle
Materials	Steel - Medium Carbon, Steel - Pre-Chromed
Technology	Rotary Friction Welding
Geometry	Bar to Bar

Application	Universal joint assembly with welded extension shaft
Materials	Steel - Low Carbon, Steel - Medium Carbon
Technology	Rotary Friction Welding
Geometry	Tube to Bar

Application	Countersinks. High-speed steel heads welded to mild-steel shanks.
Materials	Steel - Low Carbon
Technology	Rotary Friction Welding
Geometry	Bar to Bar

Application
Materials	Steel - Medium Carbon Alloy
Technology	Rotary Friction Welding
Geometry	Bar to Bar

Application
Materials	Steel - Medium Carbon Alloy
Technology	Rotary Friction Welding
Geometry	Bar to Bar

Application	Constant Velocity Joint
Materials	Steel - Medium Carbon Alloy
Technology	Rotary Friction Welding
Geometry	Tube to Tube

Application	Speed selector shaft. Mild steel yoke welded to SAE1045 shaft replaced pinned assembly.
Materials	Steel - Low Carbon, Steel - Medium Carbon
Technology	Rotary Friction Welding
Geometry	Bar to Plate

Application	Cross-section of hydraulic jack showing two tubularwelds which were made simultaneously to the base plate
Materials	Steel - Low Carbon
Technology	Rotary Friction Welding
Geometry	Tube to Plate

Application	Automotive hydraulic jack. Fabricated from tubing and plate stock.
Materials	Steel - Low Carbon
Technology	Rotary Friction Welding
Geometry	Tube to Plate

Application	Starter pinion assembly. Sintered steel gear welded to sleeve.
Materials
Technology	Rotary Friction Welding
Geometry	Tube to Plate

Application	Viscous drive fan shaft couplings replace forgings.
Materials	Steel - Low Carbon
Technology	Rotary Friction Welding
Geometry	Tube to Plate

Application	Alternator bracket. Barstock welded to plate, replaced forging.
Materials
Technology	Rotary Friction Welding
Geometry	Bar to Plate

Application	Rolled ring gear welded to flywheel stamping produces distortion-free flywheel ring gearauto
Materials	Steel - Low Carbon, Steel - Medium Carbon
Technology	Rotary Friction Welding
Geometry	Tube to Plate

Application	Fan shaft bracket assembly. Barstock welded to plate replaces machined forging.
Materials
Technology	Rotary Friction Welding
Geometry	Bar to Plate

Application	Automatic transmission output shaft. Stamped steel flange welded to barstock.
Materials
Technology	Rotary Friction Welding
Geometry	Tube to Plate

Application	Bi-metallic engine exhaust valves showing head and stem components, as-welded valve and welded valve with flash removed by shearing.
Materials	Nickel-Based Heat Resistant, Steel - Medium Carbon Alloy
Technology	Rotary Friction Welding
Geometry	Bar to Bar

Application	Experimental hollow automotive rear axle. Tubing welded to hub forging and spline blank. Replaces solid forging for weight reduction.
Materials	Steel - Medium Carbon
Technology	Rotary Friction Welding
Geometry	Tube to Tube

Application	Flanged Axle
Materials	Steel - Medium Carbon
Technology	Rotary Friction Welding
Geometry	Bar to Bar

Application	Hollow engine valves for lightweight and liquid-cooled applications
Materials	Nickel-Based Heat Resistant, Steel - Medium Carbon Alloy
Technology	Rotary Friction Welding
Geometry	Tube to Bar

Application	Transmission part
Materials
Technology	Rotary Friction Welding
Geometry	Tube to Plate

Application	Retainer-differential bearing blank cross-section (left). Bearing housing retainer for transaxle (right).
Materials	Steel - Low Carbon
Technology	Rotary Friction Welding
Geometry	Tube to Plate

Application	Experimental chassis component
Materials	Aluminum Alloys
Technology	Rotary Friction Welding
Geometry	Tube to Plate

Application	Experimental aluminum suspension link
Materials	Aluminum Alloys
Technology	Rotary Friction Welding
Geometry	Tube to Plate

Application	Forgings can be welded to barstock, tubes, plates and the like, as shown with these drive shafts
Materials	Steel - Low Carbon, Steel - Medium Carbon
Technology	Rotary Friction Welding
Geometry	Tube to Tube

Application	Figure 2 of 2 Wheel rim cross-section
Materials	Aluminum Alloys
Technology	Rotary Friction Welding
Geometry	Tube to Tube

Application	Figure 1 of 2 Wheel rim
Materials	Aluminum Alloys
Technology	Rotary Friction Welding
Geometry	Tube to Tube

Application	Figure 2 of 2 Passenger side airbag inflator and cross-section
Materials	Aluminum Alloys
Technology	Rotary Friction Welding
Geometry	Tube to Tube

Application	Figure 1 of 2 Passenger side airbag inflator and cross-section
Materials	Aluminum Alloys
Technology	Rotary Friction Welding
Geometry	Tube to Tube

Application	Side-impact airbag inflators
Materials	Steel - Low Carbon, Steel - Medium Carbon
Technology	Rotary Friction Welding
Geometry	Tube to Tube

Application	Driver and passenger side airbag inflators
Materials	Aluminum
Technology	Rotary Friction Welding
Geometry	Tube to Tube

Application	Hybrid passenger side airbag inflator
Materials	Aluminum
Technology	Rotary Friction Welding
Geometry	Tube to Tube

Application	Passenger side airbag
Materials	Aluminum Alloys
Technology	Rotary Friction Welding
Geometry	Tube to Plate

Application	Driver side airbag inflator - cross-section
Materials	Aluminum Alloys
Technology	Rotary Friction Welding
Geometry	Tube to Tube

Application	Figure 2 of 2 - Transition joint for cryogenic application
Materials	Aluminum Alloys, Stainless Steel - Austenitic
Technology	Rotary Friction Welding
Geometry	Tube to Plate

Get Inspired: More than 160 parts to explore in our interactive showroom!

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Why friction welding is vital for Automotive applications

Demand for automotive airbag inflators has stimulated the increase in the number of friction welders manufactured for the automotive industry since the 1980s. That’s because advantages such as a full-penetration weld, as well as its narrow heat-affected zone have made friction welding a key method for joining fully-loaded airbag inflators. The dramatic increase in the volume of friction welding applications and equipment continues to this day. Successful material combinations include aluminum, low carbon steel, and stainless steel alloys.

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