MTI Friction Welding Brochure PDF
MTI Friction Welding Brochure PDF
MTI Friction Welding Brochure PDF
All of us at MTI
would like to extend our thanks for your interest
in our company. Manufacturing Technology, Inc.
has been a leading manufacturer of inertia, direct
drive and hybrid friction welders since 1976.
We hope that the following pages will further
spark your interest by detailing a number of our
products, services and capabilities.
We at MTI share a common goalto help you
solve your manufacturing problems in the most
efficient way possible. Combining friction welding
Table of Contents
Introduction to Friction Welding
Safety Features
Flash Removal
Weldable Combinations
Applications
Aircraft/Aerospace
Oil Field Pieces
Military
Bimetallic & Special
Agricultural & Trucking
Automotive
General
10
14
16
20
22
28
38
Special Welders
& Automated Machines
46
48
Friction Welding
What It Is
Dissimilar Materials
Manufacturing
Technology, Inc.
Friction welding
produces forged quality
joints, with a 100%
butt joint weld through
the contact area. This
solid section shows the
narrow heat-affected
weld zone and resulting
displaced material
(flash).
Transition joint
for cryogenic
application.
Inconel to
aluminum.
Information
Information
Metal combinations
not normally
considered
weldable, such as
these copper to
aluminum electrical
connectors, can be
joined in friction
welding.
Advantages
of MTIs
Welding
Process
Inertia
Friction
Welding
Advantages
The relationship of
inertia friction
welding parameter
characteristics.
welding to one.
Pre-calculable parameters for
most materials and geometry.
The process can, therefore, be
mathematically scaled (i.e.
small samples can be used for
large parts development).
No clutches, no brakes.
Weld torque is measured
indirectly by measuring the
rate of spindle speed change.
Meets Military Standard 1252
and welding specifications of
numerous large corporations
in the U.S.A.
Largest Inertia Friction Welder
has 2250 ton forge force.
Information
Advantages
The relationship of
direct-drive friction
welding parameter
characteristics.
Information
Direct Drive
& Hybrid
Friction
Welding
Induced failure
showing typical classic
Direct Drive Friction
Weld flow pattern.
Flash
Removal
Safety Features
New machines feature custom-designed
guarding with front sliding door for manual
loading and unloading of parts, and
removable, stationary guards for rear and
sides.
Physical interlocks are placed on the
sliding door and all removable guarding.
Program interlocks protect personnel and the
machine by requiring certain conditions to
be met before allowing machine movement.
These same safety features can be added
to older machines during rebuild or retrofit.
Sound enclosures are available to soften
the sound decibels of the motors. They
range from an enclosure mounted directly
on the hydraulic unit (on smaller machines),
to a complete room built around the
hydraulic unit on very large machines.
Information
MTI
Welding
Services
10
Information
Research &
Development
and Contract
Job Shop
Weldable Combinations
in Friction Welding
Zirconium Alloys
Valve Materials (Automotive)
Vanadium
Uranium
Tungsten Carbide Cemented
Tungsten
Titanium Alloys
Titanium
Thorium
Tantalum
Steel Tool
Steel Stainless
Steel Sintered
Steel Maraging
Steel Free Machining
Steel Carbon
Steel Alloys
Silver Alloys
Silver
Niobium Alloys
Niobium
Nimonic
Nickel Alloys
Nickel
Monel
Molybdenum
Magnesium Alloys
Magnesium
Lead
Iron Sintered
Copper Nickel
Copper
Columbium
Cobalt
Ceramic
Cast Iron
Carbides Cemented
Bronze
Brass
Aluminum Alloys
Aluminum
Aluminum
Aluminum Alloys
Brass
Bronze
Carbides Cemented
Cast Iron
Ceramic
Cobalt
Columbium
Copper
Copper Nickel
Iron Sintered
Lead
Magnesium
Magnesium Alloys
Molybdenum
Monel
Nickel
Nickel Alloys
Nimonic
Niobium
Niobium Alloys
Silver
Silver Alloys
Steel Alloys
Steel Carbon
Steel Free Machining
Steel Maraging
Steel Sintered
Steel Stainless
Steel Tool
Tantalum
Thorium
Titanium
Titanium Alloys
Tungsten
Tungsten Carbide Cemented
Uranium
Vanadium
Valve Materials (Automotive)
Zirconium Alloys
Information
Since dissimilar metals can often be joined, a significant cost savings can be realized by designing
bimetallic parts that use a minimum of expensive metals only where needed. Expensive forgings and
castings can sometimes be replaced with less expensive forgings welded to bar stock, tubes, and plates, or
with components created solely by welding together bar stock, tubes, and plates.
11
12
A
B
D
C
Aircraft/
Aerospace
The demand for larger aircraft
means that aero-engines are growing
in thrust, temperature, and size. To
withstand the higher temperatures,
critical aircraft and aerospace
components are being made with
materials such as superalloy,
bimetallic, stainless steel and
aluminum. These materials, which
can be difficult and many times
impossible to weld with conventional
methods, can be joined with the
friction welding process. These
higher-temperature materials, along
with the large component size,
require large amounts of weld energy
and load. In order to meet this
increasing demand, MTI designed a
2,000 ton inertia friction welder. This
is the largest friction welder made
today. In addition to these large
machines, friction welders of all sizes
are used in this industry. Aircraft/
aerospace components friction
welded include compressor rotors,
fan shafts, cluster gears, landing gear
components, bimetallic rivets and
hook bolts, aluminum heat pipes,
and cryogenic rocket components. A
special machine was designed and
built to weld injector posts in the U.S.
space shuttle main engines.
13
G
14
15
16
Oil Field
Pieces
Weld integrity is a must in
the oil field drilling industry.
Proven reliability of friction
welded connections, coupled
with the process advantages
such as being clean, fast,
consistent, and free of
operator-induced error, makes
friction welding one of the
leading methods of joining
flanges to valve bodies, drill
pipe, high-pressure hose
couplings, and manifold tubes.
A typical string of drill pipe
can be three to four miles long,
composed of 30-foot sections.
The friction welds support the
lower drill stem assembly
(made up of other drill pipes,
drill collars and the drilling bit)
and transmit the rotary torque
needed for drilling. Friction
welding produces a
metallurgical bond strong
enough to take the high torque
and highly loaded rotary
tension due to directional
drilling.
17
E
D Geological core drill. SAE4140 end blank
welded to SAE4140 tubing.
E Sucker rod. Threaded end connector to
forged sucker rod.
F Oil well drill pipe. Close-up of tooljoint to
drill pipe weld. Female end.
G Oil well drill pipe. Close-up of tooljoint to
drill pipe weld. Male end.
F
18
Military
Government agencies in the
United States and abroad rely
on MTI as their friction welding
technology source. MTIs
continued research into the
stored energy approach to
friction welding, first pioneered
by Caterpillar Tractor, Inc. and
AMF, resulted in the first military
standards written around the
inertia welding process (MILSTD-1252).
The advantages of this
process such as no smoke,
fumes or gases, or few sparks
produced, and the fact that the
process is machine-controlled,
make it suitable for use in
potentially explosive or
hazardous environments. The
machine can be fully
automated so the operator can
be safely located out of harms
way. MTIs machines and
contract welding services have
been used in military defense,
aircraft, aerospace and ground
transportation components.
19
F Experimental windscreens to
projectiles.
G Torque tubes for amphibious
personnel carrier drive shaft.
H Front bomb case assembly.
18 in. (457mm) O.D.
F
Applications Military
20
A
FPO
2
A High-explosive bomb
development sample.
2 Mortar round.
C Copper alloy band to 30 mm
steel body.
D Adjusting link for tracked
vehicle. AISI4140.
21
Applications Military
22
Bimetallic
& Special
Applications
Metal combinations not
normally considered compatible
are joined by friction welding,
such as aluminum to steel,
copper to aluminum, titanium to
copper, and nickel alloys to steel.
Since dissimilar materials can be
joined, a significant cost savings
is possible by designing
bimetallic parts that use
expensive materials only where
needed. Engine valve heads
made from a nickel-chrome alloy
for heat resistance can be
welded to an alloy steel stem for
wear resistance. A carbon steel
shaft welded to a stainless steel
stub provides corrosion
resistance in pump motors.
MTI has experience with many
bimetallic applications. Some
others include: copper to
aluminum electrical connectors,
aluminum to stainless steel
copier fuser rollers, titanium to
copper electrodes used in
seawater desalinization cells, and
stainless to alloy steel propeller
shafts for outboard motors.
23
24
Agricultural
& Trucking
Friction welding is used
extensively in the agricultural and
trucking industries because the
welds are of forged quality, with a
100% butt joint weld throughout
the contact area. This bond is
strong enough to handle the high
stress and torque required of
heavy machinery components.
Component costs can be
significantly reduced by replacing
expensive, totally-forged parts
with forged ends welded to bar or
tube stock, without a reduction in
quality.
One example of this would be
hydraulic piston rods, which have
similar-size ends, but vary in rod
diameter and length. Instead of
stocking expensive forged
components in a variety of
different diameter and length
configurations, standardized ends
could be welded to the requiredsize rod, reducing component
costs as well as physical inventory
requirements.
Other agricultural and trucking
applications include front axle
yoke shafts, rear axles, drive
shafts, and gears.
C Water pumpas
welded.
D Water pumpfinished.
E Diesel engine piston.
25
26
27
28
29
30
Automotive
Airbag Inflators
31
7
Applications Automotive
32
D
A Hollow engine valves for
lightweight and liquid-cooled
applications.
B Flanged axle.
33
H Alternator bracket. Bar stock welded to plate replaced forging.
I Viscous drive fan shaft couplings. Replace forgings.
J Starter pinion assembly. Sintered steel gear welded to sleeve.
K Automotive hydraulic jack. Fabricated from tubing and plate stock.
L Cross-section of hydraulic jack showing 2 tubular welds which were
made simultaneously to the base plate.
M Speed selector shaft. Mild steel yoke welded to SAE1045 shaft
replaced pinned assembly.
Applications Automotive
L
K
34
G
A Constant
velocity joint.
B Stem pinion.
C Forged cam shaft blank welded to forged flange.
D Forged yoke welded to bar stock for manufacture of tilt-steering shaft.
E Universal joint assembly with welded extension shaft.
F Steering shaft welded to pre-assembled knuckle.
G Water pump hub and shaft.
35
Applications Automotive
36
37
Applications Automotive
9 Wheel spindle.
38
39
Applications Automotive
40
General
As a rule of thumb, probably
all metallic engineering
materials which are forgeable,
are weldable by the friction
welding process.
Generally, the only
requirement of the component
design, is that one of the pieces
to be welded must have a
nearly-symmetrical shape
around its axis of rotation.
The second part to be joined
can be of any shape or form, as
long as the weld contact area is
a butt design. Joint
preparation is not critical
machined, saw-cut, and even
sheared surfaces are easily
welded.
Our continuing development
of new prototype applications
allows us to remain a leader in
the friction welding industry.
Contact MTI today to see how
friction welding can work for
you.
Cutting Tools
41
Waste Canisters
Spindle Blanks
Welded blanks replace
costly forgings for
machine tool spindles.
Applications General
42
F
A Check valve fitting to stamped
housing for refrigeration unit.
B Medical X-ray target.
C Disc brake for fork lift truck.
D Center screw for automotive jack.
E Golf putters.
F Axle shaft for lawn & garden
tractor.
43
G .375 in. (9.5 mm) diameter stud welded to backing plate.
H Lift screw assembly. Acme threaded bar welded to clevis
block.
I Finished ball and mounting stud.
J Flywheel ring gear for outboard motor. Forged hub welded
to stamped and heat-treated ring gear.
K Forged eye welded to bar stock.
L Actuator arm for sewing machines.
G
H
Applications General
44
E
A Composite driver
blade.
B Mining bit.
C Miniature weld
application.
D Light weight
hydraulic piston.
E High voltage
contact. Cu-Cr
to W-Cu.
F Diesel engine
cylinder.
45
Applications General
46
A
B
47
Applications General
48
Machines
49
Machines
Different combinations and modifications are possible. All machines can be equipped with automatic load and unload
devices, flash removal, and quality control machine monitors. All weld speeds are variable from 0 to maximum.
Max. Flywheel
lbft2 kgM2
Max. Tubular
Weld Area
in2 mm2
Model
RPM (Max.)
Variable
40
45,000/60,000
0.015 0.00063
500 2.22
.07 45.2
B, D, V
60
12,000/24,000
2.25 0.094
9000 40.03
.66 426
B, BX, D, V
90
12,000
5.0 0.21
13,000 57.82
1.0 645
B, BX, D, T, V
120
8,000
25 1.05
28,000 124.54
1.7 1 097
B, BX, D, T, V
150
8,000
50 2.11
50,000 222.4
2.6 1 677
B, BX, T, V
180
8,000
100 4.2
80,000 355.8
4.6 2 968
B, BX, T, V
220
6,000
600 25.3
130,000 578.2
6.5 4 194
B, BX, T, V
250
4,000
2,500 105.4
200,000 889.6
10 6 452
B, BX, T, V
300
3,000
5,000 210
250,000 1 112.0
12 7 742
B, BX, T, V
320
2,000
10,000 421
350,000 1 556.8
18 11 613
B, BX
400
2,000
25,000 1 054
600,000 2 668.8
30 19 355
B, BX
480
1,000
250,000 10 535
850,000 3 780.8
42 27 097
B, BX
750
1,000
500,000 21 070
1,500,000 6 672.0
75 48 387
B, BX
800
500
1,000,000 42 140
4,500,000 20 000
B, BX
50
Version
Different combinations and modifications are possible. All machines can be equipped with automatic load and unload
devices, flash removal, and quality control machine monitors. All weld speeds are variable from 0 to maximum.
Model
RPM (Max.)
Variable
7.5T, FW
3,000
15,000 66.7
10T, FW
3,000
15T, FW
Max. Solid
Diameter
in mm
Max. Tubular
Weld Area
in2 mm2
Version
1.07 690
B, BX, D, T, V
20,000 89
1.13 28.7
1.43 923
B, BX, D, T, V
2,500
30,000 133
1.5 38
2.0 1 290
B, BX, D, T, V
30T, FW
2,000
60,000 267
1.9 48.3
4.2 2 768
B, BX, D, T, V
45T, FW
1,500
90,000 396
2.39 60.7
6.4 4 148
B, BX, T, V
60T, FW
1,300
120,000 533
2.9 74
8.0 5 161
B, BX, T, V
100T, FW
1,000
200,000 889.6
3.57 90.7
14.2 9 219
B, BX, T, V
125t, FW
1,000
250,000 1 112
17.8 11 523
B, BX, T
150T, FW
1,000
300,000 1 332
20.0 12 903
B, BX, T
175T, FW
1,000
350,000 1 556
4.7 119.4
23.5 15 161
B, BX
200T, FW
1,000
400,000 1 780
5.0 127
26.8 17 290
B, BX
4.0 101.6
4.37 111
Machines
1.0 25.4
51
B (Box Style)
BX (Open Top)
T (Twin2 Spindles))
D (Dual-Center Drive)
Machines
V (Vertical)
54
Machines
55
Machines
52
Machines
53
Machines
56
Machines
57
Machines
58
Machines
MTI builds the largest friction welders made today. The first of these
2,000-ton axial machines, built in 1991, was designed to weld aircraft engine
alloys and components. MTI is the only manufacturer of large friction welders
over 300-ton capacity.
This brochure is 1999 by Manufacturing Technology, Inc. (MTI). All rights reserved. This brochure is distributed by MTI for
information purposes only. MTI provides the material as is without warranties of any kind, either express or implied. Duplication
of any part(s) without express written permission of MTI is strictly prohibited.