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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
GO ALL INWITH MTI'S AUTOMATED DIRECT DRIVE FRICTION WELDING
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.
Countersinks. High-speed steel heads welded to mild-steel shanks.
Twist drill blank. Welded M10 tool steel bodies to SAE4140 shanks.
Tool steel to carbon steel drill bit
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
Figure 1 of 2 Stabilizer bars. Tube welded to solid end.
Sport utility 4x4 interconnecting shaft
Front suspension struts
Drive extension (internal spline one end).
Brake caliper. Tubing joined to formed caliper.
Transmission input shaft
Air conditioner accumulator. Aluminum housing.
Wheel spindle
Transmission gear. Finished spiral bevel gear welded to tubular shaft.
Turbocharger
Front wheel drive shaft
Drive shaft
Worm gear drive shaft
Clevis
Materials:
Technology:
Geometry: Bar to Bar
Torque converter pump
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.
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.
Electric motor housing and shaft for automotive cooling fan.
Automotive transmission component. Machined tubing welded to cold-formed end.
Rear axle housing tube. Forged tube end welded to tube stock.
Automotive axle tube
Water pump hub and shaft
Steering shaft welded to pre-assembled knuckle
Universal joint assembly with welded extension shaft
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
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.
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
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
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
Figure 1 of 2 - Transition joint for cryogenic application
Solid aluminum bar to stainless steel tube
Pin heading done using interrupted weld cycle
Copier fuser roller
Electrical connector
Tensile specimen
Bi-metallic pump motor shaft. SS stub joined to CS shaft for corrosion resistance.
Marine outboard engine drive shaft
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
Cluster gear. Small finished gear welded to larger gear blank.
Oil pump gears. Welded bar stock replaces forged blanks. 15% - 30% cost reduction (depending on size and usage).
Finished gear welded to clutch drum
Pin assembly. Pre-chromed pin welded to retaining 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.
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.
Track roller. Forged halves welded together to produce track roller assemblies.
Diesel engine piston
Water pump - finished
Water pump - as welded
Diesel engine pre-combustion chamfer cross-section
Aerospace heat pipe
Lightweight piston for aircraft pump
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
Cluster gear
Tube to rotor assembly
Low compression titanium rotor assembly
Water pump gear
Figure 2 of 2 - Copper alloy rotating band radially welded to 155 mm alloy steel projectile body and cross-section
Figure 1 of 2 - Copper alloy rotating band cross-section
Impact wrench extensions
Adjusting link for tracked vehicle
Copper alloy band to 30 mm steel body
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.