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Rotary Friction Welding

Rotary Friction Welding is a solid-state process in which one part is rotated at high speed and is pressed against another part that is held stationary. The resulting friction heats the parts, causing them to forge together.

Advantages and Benefits

For your complex joining requirements, our Rotary Friction Welding solutions offer a flexible option. We are the only company offering all three types of rotary friction welding technologies – inertia, direct drive, and hybrid. Here are some reasons why this helps you:

  • Unique welding capabilities
    Rotary Friction Welding creates a 100-percent bond of the contact area – such as a full-section weld around a diameter on the OD or ID of a tube – creating joints of forged quality. The weld properties are superior to welds created with fusion processes, such as MIG or TIG welding. This results in a higher strength bond and greatly increased design flexibility of part.

  • Minimal joint preparation
    Joint preparation is minimal for the Rotary Friction Welding process. Machined, saw-cut, and even sheared surfaces are weldable. It also creates a narrow heat-affected zone, resulting in more uniform properties throughout the part, higher joint efficiencies, and stronger welds.

  • Ecologically friendly and energy efficient
    Rotary Friction Welding is an environmentally friendly process that requires no consumables, flux, filler material, or shielding gases to run. Plus, there’s no weld splatter. It’s also energy efficient because it uses the least energy consumption of all welding processes.

  • Material & Production Efficiency
    Since a friction weld is stronger than other conventional welds, it requires less raw materials to achieve the same torque and fatigue characteristics of the conventional part. This means a reduction in both raw material costs and the post-welding machining time required to remove the extra material.

  • Faster Weld Cycles
    Weld Cycle production times can be reduced, meaning that more parts can be joined in less time, since the friction welding process is significantly faster than more conventional methods of welding. Many rotary friction welds are accomplished in mere seconds.

  • Reduced Inventory to Create Part Families
    An extensive inventory of forged part families can be replaced using fewer and less expensive friction welded common components. Unique single forgings can be replaced with less expensive and commonly stocked components such as tubes, plates, and bar stock to accommodate the product range of sizes.

  • Machine Controlled Process
    The machine-controlled friction weld process is consistent and repetitive, eliminating human error while producing weld quality that is independent of an operator’s skill level. The process parameters are easily controlled, repeatable, and monitored, allowing for real-time and statistical monitoring of the parameters.

  • Join Dissimilar Materials to Reduce Material Costs
    Metal combinations not normally considered compatible using conventional welding methods can be joined by friction welding, such as aluminum to steel, copper to aluminum, titanium to copper, and nickel alloys to steel. This creates significant cost savings because engineers can design bimetallic parts that use expensive materials only where needed. Industries like automotive and aerospace will friction-weld dissimilar materials as a way of light weighting components for their applications.

Rotary Friction Welders for Aerospace​​

Putting parts in the sky all starts on the floor. Put an MTI-built friction welder on yours and see why all leading aerospace manufacturers have made the same choice.​​

Explore Machines

MTI 2000S​
Max inertia: 5,000,000 Wk²

Can your materials be friction welded?
Check MTI's Material Compatibilities  

Not seeing your combination of materials? That doesn’t mean it can’t be done. Many of our material combinations are also proprietary. That’s why several of our customers use MTI’s in-house metallurgy lab, which will test your materials for strength and durability to see if friction welding is the right process for you.

Please note Weld strength is dependent on materials & geometry.

Selected Material: Aluminum
Compatible Welds
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Not finding something? Ask
Joint Geometries
Rotary Friction Welding can join a wide range of part geometries
Tube to Tube
Tube to Tube
Tube to Plate
Tube to Plate
Tube to Bar
Tube to Bar
Tube to Disk
Tube to Disk
Bar to Bar
Bar to Bar
Bar to Plate
Bar to Plate
Process Overview

Friction Welding is more of a forging process than an actual welding process. Rotary Friction Welding is simply about using force and rotary motion to create a bond between two pieces. Key aspects of the process include:

  • 1One piece is held stationary while the other piece is rotated.
  • 2Two pieces are then brought together as force is applied.
  • 3The force and rotating motion create friction at the faying surfaces, which is the interface of the parts being joined.
  • 4Friction creates heat. As a result, rubbing the two faying surfaces heats the pieces and upsetting (the bonding of the parts) begins.
  • 5The rotary friction welding process is completed when the rotation of one piece stops and the upsetting ends. The result is a part with a 100-percent bond and a joint of forged quality.

Schedule a Tour

Sometimes, it’s good to go around in circles

Learn how rotary friction welding can help you bring it all together for your next project.

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Machine Talk Blog
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Featured Videos

Direct Drive Friction Welding for Banjo and Trailer Axles
Direct Drive Friction Welding for Banjo and Trailer Axles
Rotary Friction Direct Drive Welder - SPARTAN 5 Ton
Rotary Friction Direct Drive Welder - SPARTAN 5 Ton
Rotary Friction Direct Drive Welder for Prop Shaft Assemblies - Model 40T
Rotary Friction Direct Drive Welder for Prop Shaft Assemblies - Model 40T
Automation used in Friction Welding Systems
Automation used in Friction Welding Systems
Inertia Friction Welder for Auto and Large Engine Pistons - Model 300BXM
Inertia Friction Welder for Auto and Large Engine Pistons - Model 300BXM
MTI Whiteboard Wednesdays: Rotary Friction Welding Upset Control- Part 3
MTI Whiteboard Wednesdays: Rotary Friction Welding Upset Control- Part 3
MTI Whiteboard Wednesdays: Rotary Friction Welding Upset Control- Part 2
MTI Whiteboard Wednesdays: Rotary Friction Welding Upset Control- Part 2
MTI Whiteboard Wednesdays: Rotary Friction Welding Upset Control- Part 1
MTI Whiteboard Wednesdays: Rotary Friction Welding Upset Control- Part 1
Inertia Friction Welder for Hollow Piston Assemblies - Model 90B
Inertia Friction Welder for Hollow Piston Assemblies - Model 90B
Inertia Friction Welder for Automotive Axle Tubes - Model 250B
Inertia Friction Welder for Automotive Axle Tubes - Model 250B
Inertia Friction Welder for Aircraft Engine Components - Model 480 S
Inertia Friction Welder for Aircraft Engine Components - Model 480 S
Inertia Friction Welder for Aircraft Engine Components - Model 800B
Inertia Friction Welder for Aircraft Engine Components - Model 800B
Inertia Friction Welder for Drill Pipe - Model 400BX
Inertia Friction Welder for Drill Pipe - Model 400BX
Inertia Friction Welder for Aerospace Component - Model 480B
Inertia Friction Welder for Aerospace Component - Model 480B
Inertia Friction Welder for Marine Engine Valves - Model 400T
Inertia Friction Welder for Marine Engine Valves - Model 400T
Inertia Friction Welder for Ordinance Casings - Model 300bx
Inertia Friction Welder for Ordinance Casings - Model 300bx
Inertia Friction Welder for Drill Pipe - Model 320BX
Inertia Friction Welder for Drill Pipe - Model 320BX
Inertia Friction Welder for Steel Diesel Piston Assemblies - Model 300B
Inertia Friction Welder for Steel Diesel Piston Assemblies - Model 300B
Inertia Friction Welder for Diesel Pistons - Model 300B
Inertia Friction Welder for Diesel Pistons - Model 300B
Inertia Friction Welder for Clutch Housing - Model 250BX
Inertia Friction Welder for Clutch Housing - Model 250BX
Inertia Friction Welder for Automated Work Cell - Model 250
Inertia Friction Welder for Automated Work Cell - Model 250
Inertia Friction Welder for Marine Engine Drive Shafts - Model 180B
Inertia Friction Welder for Marine Engine Drive Shafts - Model 180B
Inertia Friction Welder - Model 250B
Inertia Friction Welder - Model 250B
Inertia Friction Welder for Mud Pump Valves - Model 180B
Inertia Friction Welder for Mud Pump Valves - Model 180B
Inertia Friction Welder for Automotive Turbochargers - Model 150B
Inertia Friction Welder for Automotive Turbochargers - Model 150B
Inertia Friction Welder - Model 180B
Inertia Friction Welder - Model 180B
Inertia Rotary Friction Welder for Hollow Hydraulic Pump Piston Assemblies - Model 120B
Inertia Rotary Friction Welder for Hollow Hydraulic Pump Piston Assemblies - Model 120B
Inertia Friction Welder for Automotive Airbag Gas Generators - Model 120Bx
Inertia Friction Welder for Automotive Airbag Gas Generators - Model 120Bx
Inertia Friction Welder for Copper to Stamped Steel Compressors - Model 120B
Inertia Friction Welder for Copper to Stamped Steel Compressors - Model 120B
Inertia Friction Welder for Bi-Metallic Automotive Engine Valves - Model 90B
Inertia Friction Welder for Bi-Metallic Automotive Engine Valves - Model 90B
Inertia Friction Welder for Automotive Airbag Vessels and Igniters - Model 90B
Inertia Friction Welder for Automotive Airbag Vessels and Igniters - Model 90B
Inertia Friction Welder for Bi-Metallic Titanium Alloy Aircraft Rivets - Model 40
Inertia Friction Welder for Bi-Metallic Titanium Alloy Aircraft Rivets - Model 40
Inertia Friction Weld Process - German
Inertia Friction Weld Process - German
Inertia Friction Weld Process - Chinese
Inertia Friction Weld Process - Chinese
Tri Mode Rotary Friction Welder for Max Forge Force Weld - Model 300T
Tri Mode Rotary Friction Welder for Max Forge Force Weld - Model 300T
Tri-Mode Rotary Friction Welder - Model 3T
Tri-Mode Rotary Friction Welder - Model 3T
Twin Mode Rotary Friction Welder for Stabilizer Bars - Model 120BX
Twin Mode Rotary Friction Welder for Stabilizer Bars - Model 120BX
Vertical Rotary Friction Inertia Welder for Automotive Airbag Canisters - Model 120V
Vertical Rotary Friction Inertia Welder for Automotive Airbag Canisters - Model 120V
Vertical Rotary Friction Inertia Welder for Automotive Airbags - Model 120V
Vertical Rotary Friction Inertia Welder for Automotive Airbags - Model 120V
Vertical Rotary Friction Inertia Welder for Torque Converters - Model 120V
Vertical Rotary Friction Inertia Welder for Torque Converters - Model 120V
Rotary Friction Direct Drive Welder: Stubs to Tubes for Automotive Transaxle Assemblies - Model 15T
Rotary Friction Direct Drive Welder: Stubs to Tubes for Automotive Transaxle Assemblies - Model 15T
Rotary Friction Direct Drive Welder for Hydraulic Cylinder Rods - Model 60T
Rotary Friction Direct Drive Welder for Hydraulic Cylinder Rods - Model 60T
Rotary Friction Direct Drive Welder for Automotive Transaxle Drive Shaft Assemblies - Model 30T
Rotary Friction Direct Drive Welder for Automotive Transaxle Drive Shaft Assemblies - Model 30T
Rotary Friction Direct Drive Welder for Automotive Transaxle Drive Shafts - Model 15T
Rotary Friction Direct Drive Welder for Automotive Transaxle Drive Shafts - Model 15T
Rotary Friction Direct Drive Welder for Tube Axle Housings - Model 60T
Rotary Friction Direct Drive Welder for Tube Axle Housings - Model 60T
Rotary Friction Direct Drive Welder for Oil & Gas Well Valves - Model 40T
Rotary Friction Direct Drive Welder for Oil & Gas Well Valves - Model 40T
Rotary Friction Direct Drive Welder for Torque Conv Automation - Model 15T
Rotary Friction Direct Drive Welder for Torque Conv Automation - Model 15T
Rotary Friction Direct Drive Welder - Model 300T
Rotary Friction Direct Drive Welder - Model 300T
Rotary Friction Direct Drive Welder for Flash Turning Operation - Model 200T
Rotary Friction Direct Drive Welder for Flash Turning Operation - Model 200T
Rotary Friction Direct Drive Welder for Engine Turbocharger Shafts - Model 350T
Rotary Friction Direct Drive Welder for Engine Turbocharger Shafts - Model 350T
MTI Whiteboard Wednesdays: Near Net Shape Additive Manufacturing
MTI Whiteboard Wednesdays: Near Net Shape Additive Manufacturing
MTI Whiteboard Wednesdays: Bi-Metallic Friction Welding
MTI Whiteboard Wednesdays: Bi-Metallic Friction Welding
MTI Whiteboard Wednesdays: Hybrid Process
MTI Whiteboard Wednesdays: Hybrid Process
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MTI Whiteboard Wednesdays: Which Method Is Best?
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MTI Whiteboard Wednesdays: Direct Drive Process
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MTI Whiteboard Wednesdays: Inertia Process
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MTI Whiteboard Wednesdays: Rotary Friction Welding
Inertia Friction Welder for Engine Valves - Model 90B
Inertia Friction Welder for Engine Valves - Model 90B
Inertia Friction Welder for Automotive Battery Cables - Model 90B
Inertia Friction Welder for Automotive Battery Cables - Model 90B
Twin Spindle Inertia Friction Welding Machine - Model 90BX
Twin Spindle Inertia Friction Welding Machine - Model 90BX
Inertia Friction Welding Demonstration - Manufacturing Technology, Inc.
Inertia Friction Welding Demonstration - Manufacturing Technology, Inc.
Inertia Friction Welder for Torque Converters - Model 35T
Inertia Friction Welder for Torque Converters - Model 35T
Rotary Friction Direct Drive Welder for Hydraulic Cylinder Rods - Model 80T
Rotary Friction Direct Drive Welder for Hydraulic Cylinder Rods - Model 80T
Inertia Friction Welder for Drill Pipe - Model 320BX
Inertia Friction Welder for Drill Pipe - Model 320BX
Inertia Friction Welder for Automated Cells - Model 180Bx
Inertia Friction Welder for Automated Cells - Model 180Bx
Inertia Friction Welder for Turbochargers - Model 120B
Inertia Friction Welder for Turbochargers - Model 120B

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+1 574-233-9490

1702 West Washington, South Bend, IN 46628 USA | +1 574-233-9490

Manufacturing Technology, Inc. (MTI) is a privately-held, fourth-generation company headquartered in South Bend, Indiana, specializing in transformational, custom-engineered friction welding and resistance welding solutions for manufacturing processes. Our leading-edge expertise is available worldwide on-site for industry applications such as aerospace, oil and gas, automotive, agriculture, construction, consumer product electronics, and military.

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