Advanced Welding Solutions for Rail Manufacturing
High-performance Friction Stir Welding systems for railcar structures - delivering strength, consistency, and production efficiency at scale.
Through MTI’s partnership with STIRTEC, railway companies across the Americas, EU, India, Australia, and New Zealand gain access to advanced friction stir welding systems engineered for high-performance railway and railcar applications.
Friction Stir Welding for Railcar Structures
Friction Stir Welding (FSW) is a solid-state joining process that uses a rotating pin tool to generate heat and “stir” the material of two components together along the bond line, creating a high-quality weld without melting the base materials.
Because the FSW process occurs below the melting point of the materials, manufacturers in the railway sector benefit from a more controlled and reliable joining process, including the following advantages:
- Ideal for large aluminum extrusions and panel assemblies
- Enables long, continuous welds with minimal distortion
- Improves structural integrity and fatigue performance
- Reduces post-processing and rework
- Supports high-speed rail, metro, and passenger coach manufacturing
For railcar manufacturing, FSW offers a reliable solution for producing durable, high-integrity joints.
GG Series Friction Stir Welder
Discover MTI’s most versatile heavy-duty friction stir welding machine. The GG Series is built for large, complex railcar structures and thick-section materials that many conventional friction-stir welding systems cannot accommodate.
- Rigid gantry architecture for maximum stability
- 5-axis gimbaled weld head for true 3D welding
- Handles oversized components and complex geometries
- Optional extendable rail system, machine-based, and high-capacity rotary table
LS Series Friction Stir Welder
The LS Series delivers unmatched performance for railcar panels, extrusions, and long, continuous welds. This machine supports efficient, repeatable stir welding on large components where consistency and throughput matter most.
- C-frame design with modular base to scale the machine footprint
- Optimized for long, continuous welds
- Optional dual-head configuration for high throughput
- Ideal for structural panel assemblies
Digital Control for Consistent Weld Quality
STIRlytics® strengthens weld consistency by bringing advanced digital process control to MTI’s friction stir welding machines. STIRlytics® weld controls achieve precise, reliable welds by providing the following:
- Closed-loop force and position control
- Real-time weld monitoring and traceability
- ISO 25239-compliant weld quality
- Built on SIEMENS Sinumerik ONE CNC controller
- Remote diagnostics and Industry 4.0 connectivity
For manufacturers producing critical railway components, STIRlytics® helps ensure every weld is backed by data, consistency, and the advanced technology needed for long-term performance.
Process Expertise Meets Machine Excellence
MTI announced a strategic partnership with STIRTEC GmbH in March 2025 to deliver best-in-class Friction Stir Welding (FSW) solutions globally.
STIRTEC is a recognized leader in friction-stir welding innovation. Through their STIRlytics® platform, they bring advanced industry expertise, including:
- High welding speeds
- Advanced pin tool design
- Real-time process monitoring
- System performance
Their cutting-edge FSW process experience enables MTI to deliver a broader portfolio of machines tailored to diverse materials, applications, and industry requirements, especially within the evolving railroad and railcar manufacturing landscape.
STIRTEC is a recognized leader in friction-stir welding innovation. Through their STIRlytics® platform, they bring advanced industry expertise, including:
- High welding speeds
- Advanced pin tool design
- Real-time process monitoring
- System performance
Their cutting-edge FSW process experience enables MTI to deliver a broader portfolio of machines tailored to diverse materials, applications, and industry requirements, especially within the evolving railroad and railcar manufacturing landscape.
MTI specializes in evolving, custom-engineered friction welding solutions that strengthen modern manufacturing processes. Across four generations, we have helped customers solve complex joining challenges with proven technology, advanced machines, and application-specific expertise.
Our capabilities include:
- More than 100 years of machine tool design and manufacturing experience
- Contract friction welding services supporting aerospace, automotive, and other demanding industrial sectors since the 1990s
As MTI renewed its focus on the friction stir welding machine market, it partnered with STIRTEC to expand its capabilities.
By combining MTI’s global manufacturing expertise with STIRTEC’s innovation in friction stir welding, the partnership delivers advanced solutions that support next-generation railway applications. Our fully integrated FSW solutions combine process control, machine performance, and digital connectivity. Together, we provide unmatched value and weld quality for the rail industry worldwide.
Advanced Rail Friction Welding with STIRTEC
Leverage STIRTEC’s advanced friction welding technologies to move railway and railcar manufacturing forward. Built for demanding rail applications, our solutions help companies improve weld quality, increase production efficiency, and support safer, more reliable performance across the railway sector.
For companies producing longer rail sections, structural assemblies, and durable railcar components, repeatability is essential. STIRTEC’s welding systems are engineered to deliver precise, consistent results. Automation is also part of our customization of rail welding machines. With repeatability as an advantage, manufacturers can maintain tighter quality standards and efficient production.
STIRTEC’s STIRlytics digital process control technology gives manufacturers greater visibility into every stage of the weld. With tighter control over critical parameters, customers can produce precise, high-integrity joints. For the modern railway sector, this level of digital oversight strengthens quality assurance. It improves industrial reliability and helps ensure every weld supports long-term performance in the field.
Our Commitment
Dedication to Precision, Consistency, and Quality
At MTI, precision, consistency, and quality are built into every process. Our team is committed to providing the highest possible degree of safety, weld integrity, and process control for customers across the railway sector and other demanding industries.
Friction Welding Machines for the Rail Industry
MTI’s advanced friction welding machines are engineered to meet the demanding requirements of the railway industry. Designed for precision, durability, and scalability, our systems support a wide range of railway applications, from joining critical railway components to producing high-performance railcar structures.
Explore the capabilities of MTI’s industry-leading technology and discover how our friction welding solutions can advance your manufacturing operations.
Friction Welding Machines for Aerospace
MTI’s advanced friction welding machines are engineered to meet the demanding requirements of the railway industry. Designed for precision, durability, and scalability, our systems support a wide range of railway applications, from joining critical railway components to producing high-performance railcar structures.
Explore the capabilities of MTI’s industry-leading technology and discover how our friction welding solutions can advance your manufacturing operations.
Future Capability: Long Rail Welding
In the railroad industry, weld quality is critical. However, traditional methods, such as thermite and flash butt welding, can introduce variability into the joining process. MTI’s advanced friction welding solutions offer a more controlled solid-state process, reducing the risk of fractures, eliminating inclusions, and producing a narrower heat-affected zone.
MTI is actively advancing Linear Low Force Friction Welding solutions for long rail applications. In a Federal Railroad Administration (FRA) project, MTI is working with the University of Notre Dame to design and build a full-scale rail joining machine capable of welding a full section on 136-lb rail. With MTI’s Linear Low Force welding technology, this project aims to reduce installation costs for conventional welded rail.
This innovative technology is designed to deliver precise, repeatable joining for continuous rail production and large-scale railway applications.
FRICTION STIR WELDING
Friction Stir Welding is vital for sensitive rail parts to ensure safety. Our machines enable the joining of rail coaches and other railway components.
LOW FORCE FRICTION WELDING
MTI is the only company in the world to have developed and designed Low Force Friction Welding machines operating in production today.
LINEAR FRICTION WELDING
MTI is the leading manufacturer to have multiple Linear Friction Welding machines in operation around the globe.
Browse MTI Sample Parts
Discover applications that are feasible for your project with our sample friction-welded parts catalog.
Contract Manufacturing Services
Beyond building advanced friction welding machines, we operate them too. Leverage our expertise and state-of-the-art technology with our Contract Friction Welding services. We offer a fully supported manufacturing process from prototyping to full production.
Contract Manufacturing Services
Beyond building advanced friction welding machines, we operate them too. Leverage our expertise and state-of-the-art technology with our Contract Friction Welding services. We offer a fully supported manufacturing process from prototyping to full production.
Rail Friction Welding Machines for R&D
Our in-house systems are ready to support testing for your next railway application
Test your materials, applications, and joining process requirements on MTI’s in-house machines. Our research and development capabilities help manufacturers evaluate feasibility, refine weld parameters, and move forward with greater confidence before full-scale production begins.
MTI’s LS-1 located at our Manufacturing Services facility in South Bend.
Learning Center
Case Studies
Videos
Get the information you need, before you need it — free and straight to your inbox from industry experts.