Bi-metallic application linear friction welding of copper alloy block to aluminum plate
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Bi-metallic application linear friction welding of copper bars to aluminum plate top angle view
Linear friction welding of all shapes of parts
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Larger custom aluminum sheet sizes created by friction stir welding from smaller stock pieces
Top view - friction stir welded MTI business card .100" thick aluminum plate
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.
4' section view of joining of multiple aluminum extrusion panel sections up to 50' long via dual weld head (upper & lower) welds
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
Multiple pieces of High Strength Steel Alloy joined in a single friction stir pass for low heat input sheet joining (reducing distortion)
Drive shaft sectioned part front view - tool exit hole shown -lightweighting vehicle while maintaining or increasing durability
Welded machine tool spindle blank. Replaces costly forging.
Welded machine tool spindle blank - as machined
Welded machine tool spindle blank. Replaces costly forging.
Welded machine tool spindle blank - as machined
Keyway and T-slot cutters. Welded blanks made from AISI6145 shanks and M4 tool steel heads.
Materials: Steel - Medium Carbon, Steel - Tool
Technology: Rotary Friction Welding
Geometry: Bar to Plate
Countersinks. High-speed steel heads welded to mild-steel shanks.
Materials: Steel - Medium Carbon, Steel - Tool
Technology: Rotary Friction Welding
Geometry: Bar to Plate
Twist drill blank. Welded M10 tool steel bodies to SAE4140 shanks.
Materials: Steel - Medium Carbon, Steel - Tool
Technology: Rotary Friction Welding
Geometry: Bar to Bar
Tool steel to carbon steel drill bit
Materials: Steel - Medium Carbon, Steel - Tool
Technology: Rotary Friction Welding
Geometry: Bar to Bar
Air conditioner rotor assembly. Outer rotor pole is welded to inner rotor pole then this assembly is welded to pulley blank.
Bumper shocks. Tubing welded to stamping for impact absorbing bumper mounts.
Shock absorber base cup. Weld between threaded stud and base cup firmly traps washer in place.
Input shaft for automotive transmission. Stamped hub to machined barstock.
Figure 2 of 2 Welded stabilizer bar cross-section
Materials: Steel - Low Carbon, Steel - Medium Carbon
Technology: Rotary Friction Welding
Geometry: Tube to Bar
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
Sport utility 4x4 interconnecting shaft
Materials: Steel - Low Carbon, Steel - Medium Carbon
Technology: Rotary Friction Welding
Geometry: Tube to Tube
Front suspension struts
Drive extension (internal spline one end).
Materials: Steel - Low Carbon, Steel - Low Carbon Alloy (Gear Steel)
Technology: Rotary Friction Welding
Geometry: Tube to Tube
Brake caliper. Tubing joined to formed caliper.
Transmission input shaft
Materials: Steel - Low Carbon, Steel - Low Carbon Alloy (Gear Steel)
Technology: Rotary Friction Welding
Geometry: Bar to Plate
Air conditioner accumulator. Aluminum housing.
Wheel spindle
Materials: Steel - Low Carbon, Steel - Medium Carbon
Technology: Rotary Friction Welding
Geometry: Tube to Plate
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
Turbocharger
Materials: Nickel-Based Heat Resistant, Steel - Medium Carbon
Technology: Rotary Friction Welding
Geometry: Tube to Disk
Front wheel drive shaft
Drive shaft
Materials: Steel - Low Carbon, Steel - Medium Carbon
Technology: Rotary Friction Welding
Geometry: Tube to Tube
Worm gear drive shaft
Materials: Steel - Low Carbon, Steel - Medium Carbon
Technology: Rotary Friction Welding
Geometry: Bar to Bar
Clevis
Materials:
Technology:
Geometry: Bar to Bar
Torque converter pump
Materials: Steel - Low Carbon, Steel - Medium Carbon
Technology: Rotary Friction Welding
Geometry: Tube to Tube
Torque converter cover. Three mounting nuts welded to cover for mounting of flywheel ring gear.
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
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
Electric motor housing and shaft for automotive cooling fan.
Materials: Steel - Low Carbon, Steel - Medium Carbon
Technology: Rotary Friction Welding
Geometry: Tube to Disk
Automotive transmission component. Machined tubing welded to cold-formed end.
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
Automotive axle tube
Materials: Steel - Low Carbon, Steel - Medium Carbon
Technology: Rotary Friction Welding
Geometry: Tube to Bar
Water pump hub and shaft
Steering shaft welded to pre-assembled knuckle
Materials: Steel - Medium Carbon, Steel - Pre-Chromed
Technology: Rotary Friction Welding
Geometry: Bar to Bar
Universal joint assembly with welded extension shaft
Materials: Steel - Low Carbon, Steel - Medium Carbon
Technology: Rotary Friction Welding
Geometry: Tube to Bar
Countersinks. High-speed steel heads welded to mild-steel shanks.
Constant Velocity Joint
Cross-section of hydraulic jack showing two tubularwelds which were made simultaneously to the base plate
Automotive hydraulic jack. Fabricated from tubing and plate stock.
Starter pinion assembly. Sintered steel gear welded to sleeve.
Viscous drive fan shaft couplings replace forgings.
Alternator bracket. Barstock welded to plate, replaced forging.
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
Fan shaft bracket assembly. Barstock welded to plate replaces machined forging.
Automatic transmission output shaft. Stamped steel flange welded to barstock.
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
Experimental hollow automotive rear axle. Tubing welded to hub forging and spline blank. Replaces solid forging for weight reduction.
Flanged Axle
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
Transmission part
Retainer-differential bearing blank cross-section (left). Bearing housing retainer for transaxle (right).
Experimental chassis component
Experimental aluminum suspension link
Figure 2 of 2 Wheel rim cross-section
Figure 1 of 2 Wheel rim
Figure 2 of 2 Passenger side airbag inflator and cross-section
Figure 1 of 2 Passenger side airbag inflator and cross-section
Side-impact airbag inflators
Materials: Steel - Low Carbon, Steel - Medium Carbon
Technology: Rotary Friction Welding
Geometry: Tube to Tube
Driver and passenger side airbag inflators
Hybrid passenger side airbag inflator
Passenger side airbag
Driver side airbag inflator - cross-section
Figure 2 of 2 - Transition joint for cryogenic application
Materials: Aluminum Alloys, Stainless Steel - Austenitic
Technology: Rotary Friction Welding
Geometry: Tube to Plate
Figure 1 of 2 - Transition joint for cryogenic application
Materials: Aluminum Alloys, Nickel-Based Heat Resistant
Technology: Rotary Friction Welding
Geometry: Tube to Plate
Solid aluminum bar to stainless steel tube
Pin heading done using interrupted weld cycle
Copier fuser roller
Materials: Aluminum Alloys, Stainless Steel - Austenitic
Technology: Rotary Friction Welding
Geometry: Tube to Disk
Electrical connector
Tensile specimen
Bi-metallic pump motor shaft. SS stub joined to CS shaft for corrosion resistance.
Materials: Stainless Steel - Austenitic, Steel - Low Carbon
Technology: Rotary Friction Welding
Geometry: Bar to Plate
Marine outboard engine drive shaft
Materials: Stainless Steel - Precipitation Hardening, Steel - Medium Carbon Alloy
Technology: Rotary Friction Welding
Geometry: Bar to Bar
Bar stock welded to clevis forging for manufacture of large (5 inches (127 mm) diameter and larger) piston rods
Hydraulic piston rod
Track adjusting yoke for commercial tracked vehicles
Hydraulic piston rods. Rod eyes cut from heavy-wall tubing welded to pre-chromed bar stock.
Torque rod. Forged eye welded to various barstock lengths.
Truck rear suspension link welded on twin 150 Inertia Welder. Ends are oriented to within ±1° of each other.
Lift link-ball socket. Forged couplings welded to tubing and barstock.
Lift screw. Roll threaded stock cut to length and welded to screw machined ends.
Chain drive sprocket
Two pre-finished transmission gears welded using precision piloted tooling
Materials: Steel - Low Carbon Alloy (Gear Steel)
Technology: Rotary Friction Welding
Geometry: Tube to Tube
Cluster gear. Small finished gear welded to larger gear blank.
Materials: Steel - Low Carbon Alloy (Gear Steel)
Technology: Rotary Friction Welding
Geometry: Tube to Disk
Oil pump gears. Welded bar stock replaces forged blanks. 15% - 30% cost reduction (depending on size and usage).
Finished gear welded to clutch drum
Materials: Steel - Low Carbon, Steel - Low Carbon Alloy (Gear Steel)
Technology: Rotary Friction Welding
Geometry: Tube to Plate
Pin assembly. Pre-chromed pin welded to retaining plate
Materials: Steel - Low Carbon, Steel - Medium Carbon
Technology: Rotary Friction Welding
Geometry: Bar to Plate
Front axle yoke shaft for four-wheel-drive vehicles - bar stock to yoke forging
Universal joint clevis
Power control drive shaft for motor grader. Inertia weldment replaces upset forging (left) which required five straightening operations
Forged wheel spindles joined to 5 inches (127 mm) diameter - 5 inches (12.7 mm) wall tubing to produce trailer axles.
Materials: Steel - Low Carbon, Steel - Medium Carbon
Technology: Rotary Friction Welding
Geometry: Tube to Tube
Truck trailer brake S-cam
Rear axles for tractors - 4 inches (101.6 mm) diameter bar stock welded to hub forging
Steel-backed, bronze-laminate thrust washers and sleeves welded together to produce track roller bushings. Replaced costly, solid bronze castings.
Materials: Copper Alloy, Steel - Low Carbon
Technology: Rotary Friction Welding
Geometry: Tube to Plate
Track roller. Forged halves welded together to produce track roller assemblies.
Diesel engine piston
Water pump - finished
Materials: Stainless Steel - Martensitic, Steel - Medium Carbon
Technology: Rotary Friction Welding
Geometry: Bar to Bar
Water pump - as welded
Materials: Stainless Steel - Martensitic, Steel - Medium Carbon
Technology: Rotary Friction Welding
Geometry: Bar to Bar
Diesel engine pre-combustion chamfer cross-section
Aerospace heat pipe
Lightweight piston for aircraft pump
Materials: Stainless Steel - Precipitation Hardening
Technology: Rotary Friction Welding
Geometry: Tube to Tube
Aircraft hook bolts
Stator vane adjustor lever
Bi-metallic aircraft rivets
Ball screw actuator
Left: Stator vane root weld - as machined, Center: Stator vane root weld - with flash removed, Right: Stator vane root weld - as welded.
Military jet engine fan shaft, cross-section - as machined
Commercial jet engine fan shaft - as welded
Fan shaft for military jet engine
Forged clevis to tubing for manufacture of ball screw. Actuates swing wing on F-14 fighter aircraft.
Military jet engine compensating shaft - as welded
Bosses welded to accumulator housing
Extension welded to four-blade propeller hub forging
Jet engine component - as machined
Landing gear component
Landing gear drag brace
Jet engine compressor rotor - as welded
Fan blade rotor
Cluster gear cross section
Materials: Steel - Low Carbon Alloy (Gear Steel)
Technology: Rotary Friction Welding
Geometry: Tube to Tube
Cluster gear
Materials: Steel - Low Carbon Alloy (Gear Steel)
Technology: Rotary Friction Welding
Geometry: Bar to Plate
Tube to rotor assembly
Low compression titanium rotor assembly
Water pump gear
Materials: Steel - Low Carbon Alloy (Gear Steel), Steel - Medium Carbon
Technology: Rotary Friction Welding
Geometry: Bar to Plate
Figure 2 of 2 - Copper alloy rotating band radially welded to 155 mm alloy steel projectile body and cross-section
Materials: Copper Alloy, Steel - Medium Carbon
Technology: Rotary Friction Welding
Geometry: Tube to Disk
Figure 1 of 2 - Copper alloy rotating band cross-section
Materials: Copper Alloy, Steel - Medium Carbon
Technology: Rotary Friction Welding
Geometry: Tube to Disk
Impact wrench extensions
Adjusting link for tracked vehicle
Copper alloy band to 30 mm steel body
Materials: Copper Alloy, Steel - Medium Carbon Alloy
Technology: Rotary Friction Welding
Geometry: Tube to Bar
Mortar round
Mid-case bomb assembly - 18 inches (457 mm) outside diameter, 43 in2 (27 740 mm2) weld area
Front bomb case assembly - 18 inches (457 mm) outside diameter
Drive shaft torque tubes for amphibious personnel carrier
Experimental windscreens to projectiles
Closure for smoke mortar fill hole
Experimental machine gun barrel liner
Figure 2 of 2 - Fuze liners. Drawn thin-wall tubing to heavy-wall tubing rings.
Figure 1 of 2 - Fuze liners. Drawn thin-wall tubing to heavy-wall tubing rings.
Fuze liner
Figure 2 of 2 - Formed cap welded to tubing for manufacture of bomblet
Experimental aluminum smoke mortar
Figure 1 of 2 - Formed cap welded to tubing for manufacture of bomblet
Oil well head manifold tubing cross-section
Oil well drill pipe. Close-up of tooljoint to drill pipe weld - male end.
Oil well drill pipe. Close-up of tooljoint to drill pipe weld - female end.
Sucker rod. Threaded end connector welded to forged sucker rod.
Geological core drill - end blank welded to tubing
High-pressure valve body weld cross-section
Butterfly valves. Wrought stainless steel extension welded to investment cast stainless steel butterfly valver: Stator vane root weld - with flash removed, Right: Stator vane root weld - as welded.
High-pressure valve body. Forged flanges welded to forged valve body.