Machine Talk Blog

GLASGOW — Two MTI-built rotary friction welding machines have found a new and purposeful home at the University of Strathclyde’s Advanced Forming Research Centre (AFRC), which specializes in innovative manufacturing technologies, metal forming and forging research.

When it comes to aerospace and automotive applications, bigger isn't always better.  In fact, companies invest a lot of time and money into figuring out how to trim the weight of their critical parts.

The world of friction welding is vast -- and so is the vocabulary used to describe it! We've compiled a list of the most commonly used friction welding terms -- from machine components to MTI's processes -- to help you grow your engineering mind!

DETROIT – The first and only linear friction welder capable of full-sized part development in North America is now fully operational and ready for project work at LIFT - Lightweight Innovations for Tomorrow, a national manufacturing innovation facility operated by the American Lightweight Materials Innovation Institute, in Detroit.

Steel and Inconel: they look similar, but metallurgically speaking, they’re two very different materials. They melt at different temperatures, they have different densities and their forgeabilities vary greatly.

Kingswinford, UK – MTI Welding Technologies, Ltd. is building a state-of-the-art friction welding machine for a leading truck manufacturer in Europe.

South Bend, Ind. - Recently recognized for its role in high-profile space missions, Manufacturing Technology, Inc. (MTI) is gearing up to showcase its friction welding expertise to some of the biggest aerospace influencers in the nation.

The year was 1970: the Boeing 747 had just completed its first commercial flight, IBM was preparing to shake up the tech world with the floppy disk and Americans were flooding the streets, calling for stricter environmental regulations.

Friction Welding has become the premier choice for companies looking to join dissimilar metals.  Because Friction Welding is a solid-state joining process that does not require melting, it allows for the bonding of two metals, such as Copper and Aluminum, that may be impossible to join with more traditional welding techniques.

With fusion welding processes like MIG and TIG welding, it can be challenging to join dissimilar metals because they often differ substantially in composition and physical, mechanical and metallurgical properties.

At MTI’s Manufacturing Services, we do more than bond parts together; we provide you with a proven, turnkey solution. Whether you need help with just one portion of the friction welding process or want guidance every step of the way, MTI’s team of highly skilled engineers is ready to help.

Tom Budd, MTI Friction Welding Solutions Manager, poses in the MTI booth at the Pacific Design & Manufacturing Show in Anaheim, California

More companies than ever now understand the benefits of Friction Welding, thanks to MTI's recent appearance at the Pacific Design & Manufacturing Show.

Jamie Clews (right) looks over the controls on a machine.

In part five of MTI's Eyes of an Engineer series, we sit down with Global Controls Technical Lead Jamie Clews.  Read on to see how an MTI college program transformed into a full-time job and a move to a new country for Jamie.

SOUTH BEND, Ind. – The friction welding experts at Manufacturing Technology, Inc. (MTI) are helping welcome the next generation of American space travel and preparing to launch NASA astronauts on missions to deep space through the world’s only exploration-class space systems: NASA’s Space Launch System (SLS) rocket, Orion spacecraft and the Exploration Ground Systems that launch these vehicles.   

SOUTH BEND, Ind. – Continuing its longtime dedication to excellence, Manufacturing Technology, Inc. (MTI) has renewed its AS9100 certification, a key quality indicator for companies working in the aerospace and defense industries.

As the global leader in Friction Welding, Manufacturing Technology, Inc. (MTI) is always looking forward, searching for ways to help put the future of innovative manufacturing into customers’ hands.

  SOUTH BEND, IN - OCTOBER 9, 2018: Manufacturing Technology, Inc. (MTI) has shipped North America’s first linear friction welder capable of full sized part development to the LIFT - Lightweight Innovations for Tomorrow facility in Detroit where it will contribute to cutting edge lightweighting research in the automotive and aerospace sectors.

PICTURED FROM LEFT TO RIGHT: Jamie Clews (MTI Global Controls Technical Lead), Brian Roberts (MTI Manufacturing Operations Lead), Scott Knoll (Amerisure Senior Risk Management Consultant), Daniel C. Adams (MTI President & CEO), Mark Wobbe (Gibson Principal, Risk Advisor), MariClare Osborn (MTI Director of Human Resources), and Jeff Lovin (MTI Director of Technical Operations).  

SOUTH BEND, IN - SEPTEMBER 28, 2018:  Manufacturing Technology, Inc. (MTI) today was awarded for outstanding safety performance by Amerisure Insurance Company. MTI was presented the award at its world headquarters in South Bend, IN after maintaining 365 days without a recordable incident. The last time the company achieved this was in 2005.  Additionally, MTI has sustained an impressive 419 days without a loss time incident during the period beginning on July 2017 through September 2018.

For four decades, MTI has been a global leader in friction welding technology — a forging technique that offers many advantages over traditional, fusion welding. With the ability to create super-strong bonds of virtually any size, friction welding is uniquely capable of serving a broad spectrum of industries.

One industry in which we are constantly innovating, is that of aerospace. With changing priorities and advancing technologies that create more demanding joining applications, MTI is continually adapting the rotary and linear friction welding processes to meet the demands of aerospace engineers and manufacturers .

In our fourth installment of Eyes of an Engineer, we introduce you to junior service engineer James Lovell and junior design engineer Luke Barratt.  Luke and James both graduated from MTI’s apprenticeship program in February of 2018.

Discover why they chose MTI, what they learned, and where they’re headed next.

You might not realize it yet, but friction welded parts are all around us, from the cars you drive to the planes you fly in.

Here’s a look at some everyday objects you never knew were friction welded:

In our third installment of Eyes of an Engineer, we introduce you to Tori Zellerhoff and Margot Hughan.  They began working at MTI as part of their capstone thesis for Notre Dame’s Master’s Program in Entrepreneurship, Technology, & Innovation (ESTEEM).

Combining technology with entrepreneurship, the two developed a business plan and go-to-market strategy for MTI’s latest technology, low force friction welding. 

Find out how they got started, what they learned at MTI, and what they enjoyed most about the experience.

South Bend, IN - October 6, 2017:  Manufacturing Technology, Inc (MTI) opened its doors to area high schoolers in celebration of Manufacturing Day. The nation-wide event introduces the next generation of workers to high-skilled careers in modern manufacturing.

Students from Riley, Washington, and Adams High School attended the event, which was held at MTI’s world headquarters. 

SOUTH BEND, IN -- Former astronaut Brian Duffy along with representatives from NASA, Aerojet Rocketdyne, Boeing, Lockheed Martin and Orbital ATK acknowledged Manufacturing Technology, Inc (MTI) for its contributions to the NASA Space Launch System (SLS).

MTI has gained global recognition for designing and building the most advanced, customized friction welding machines—including the world’s largest inertia friction welder.

While we are proud of building the largest rotary and linear friction welders in the world, we have also designed and built hundreds of smaller friction welding machines.  And that’s where the SPARTAN product line comes in.

Unscheduled downtimes can result in significant financial losses and consume the maintenance department. That’s why refurbishing your old friction welding machine has several cost-saving advantages. 

If you’re falling behind or having difficulty meeting quality compliance, an MTI upgrade may be just what you need. 

Here are 5 signs to look for:  

Leveraging the latest in advanced rotary friction welding technology, MTI’s newest double axle machine increases efficiency, accuracy, and cost-effectiveness in axle production. 

Here are the three things you need to know about MTI’s latest double axle machine:  

PICTURED FROM LEFT TO RIGHT: Jim Hoffman (Chief Metallurgist and Quality Assurance), Sherri Lotter (Inside Sales Coordinator), Zach Danko (Process Engineer), Jordan Walser (Process Engineer), Jacob Smith (Production Manager), Gabe Hostetter (Process Engineer).

SOUTH BEND, IN - To demonstrate a continued commitment to quality, Manufacturing Technology, Inc. (MTI) announces that they have been successful in achieving Nadcap accreditation for welding at their Sheridan Street location. 

PICTURED FROM LEFT TO RIGHT: Bob Besse (MTI VP Sales & Marketing), Jeanette Lapehn (MTI Spare Parts Manager), Mike Laiman (MTI Manufacturing Services Business Unit Manager), Dan Adams (MTI President & CEO), Brian Roberts (MTI Manufacturing Operations Lead), Mohamed Elnaggar (AR Specialist Engineer), David Sherman (AR Manufacturing Engineer), Heath Cheung (AR Project Engineer), Kent Majewski (AR Associate Engineer), James Bartlett (AR Sr. Specialist Engineer).

SOUTH BEND, IN - Aerojet Rocketdyne, a subsidiary of Aerojet Rocketdyne Holdings, Inc. (NYSE: AJRD), has recognized Manufacturing Technology, Inc. (MTI) for its work on the RS-25 rocket engine, a key element of NASA’s space exploration program.  MTI was instrumental in the refurbishment of the inertia welder and production inertia welding for the RS-25 Main Injector. 

When a 261 metric ton airplane lands or a medivac helicopter is headed to the hospital—that is no time for a critical component to fail.

MTI understands this. That’s why we’re NADCAP* accredited. Our aerospace partners like GE, Pratt & Whitney, Rolls-Royce, Boeing, and Honeywell trust the quality of MTI’s welded parts.  

SOUTH BEND, IN - Ball Aerospace has recognized Manufacturing Technology, Inc. (MTI) for outstanding technical performance on the TIRS-02 Program, a NASA initiative which uses thermal infrared sensors to measure the Earth’s temperature.  MTI played an integral role by joining together titanium and copper for the TIRS-02 Cryocooler, which is used on the Landsat Data Continuity satellite.

“We were thrilled to work with Ball Aerospace and work together to find a joining solution that met their needs” said Mike Laiman, MTI’s Manufacturing Services Business Unit Manager.  “Collaboration was key to our success.”

SOUTH BEND, IN - Manufacturing Technology, Inc. (MTI) today announced changes to the company’s leadership team, as well as the addition of three outside Board of Director members.  The changes are part of the company’s focus on new product development, operations, and sales.

Dan Adams, who is currently MTI’s President and one of the company’s fourth generation owners, is assuming the role of CEO.  He will continue overseeing the company’s recently launched new product development efforts. 

Every day, the engineers at MTI are working to solve complex manufacturing challenges through diverse applications of friction welding. They design the machines that help make our customers’ parts even better — and they’re passionate about their work.

Today, we’re pleased to introduce you to three of them: JT, Matt, and Susannah. They’ll tell you how they got here, and what they love about working at MTI.

SOUTH BEND, IN – Manufacturing Technology Inc., (MTI) announced it will develop North America’s largest Linear Friction Welder, in terms of force capacity and tooling envelope, and deliver it to LIFT – Lightweight Innovations for Tomorrow – for use in lightweight metals research and development projects, based in Detroit.

Friction welding is a forging technique that produces ultra-strong bonds for diverse applications. This process has been the answer to many manufacturing and engineering challenges for over five decades. From aerospace to automotive, friction welding is continually opening the possibilities for ongoing technological advancement.

Friction welding offers a wealth of solutions to tough manufacturing problems. Thanks to key advantages — such as consistent quality, the ability to join different metals together, and reduced material waste — friction welding is a time-efficient and cost-effective way to produce new parts. Friction welding is a powerful process that not only provides forged quality components, but gives engineers the confidence that the part will meet the quality standards of their application.

SOUTH BEND, IN-  As part of an ongoing strategy of investing in and adapting to the best market opportunities, Manufacturing Technology, Inc. (MTI) is proactively realigning its US machine build and corporate operations.  This allows the company to be more cost competitive, and will result in 24 positions being eliminated or reassigned. MTI’s UK operation is not affected.

MTI’s US business is built around large complex friction welding machines, a successful niche, but only a small portion of the global market.  The global friction welding machine market is dominated by smaller automated machines.  This is a segment where the US operation has become much less cost competitive over time.

When manufacturing critical components for applications such as transportation, space flight, oil & gas, construction, and the military, quality isn’t just important — it’s absolutely essential. Implementing a trusted joining technology allows components to reach the desired quality and durability.

The International Manufacturing Technology Show (IMTS) is held every two years in Chicago giving national and international manufacturing companies an opportunity to network, learn about new technologies and engage with colleagues. This year’s IMTS wrapped up on September 17, 2016 and once again MTI was thrilled to have spent the week meeting new people, hearing about new challenges and teaching people about friction welding.

SOUTH BEND, IN - September 16, 2016: Manufacturing Technology, Inc. (MTI) reconnected with leadership guru and award-winning author David Marquet.

During an Executive Forums Leadership Summit attended by MTI and other organizations, Marquet demonstrated the importance of leading with intent. Marquet believes the ideal workplace is one where everyone participates and contributes their full intellectual capacity.

We live in the age of customization. Just about anything can be customized: cars, clothes, homes, etc. The idea of customization has been integral to the manufacturing industry for some time now. At MTI, we understand that need for being able to ensure end-results meet specific needs.

In fact, a key aspect to what we do involves taking friction welding and integrating it with a design and evaluation process that leads to either creating unique machines for the client or producing customized parts that cannot be made using traditional manufacturing processes. Being able to customize the process allows MTI clients to save time and money.

The 2016 International Manufacturing Technology Show is running from September 12-17, 2016 in Chicago, IL and MTI is there! We’ll be in the North Building, B Hall (Fabricating & Lasers), Booth N-6014 where we’ll discuss our friction welding technologies and how they can improve your manufacturing processes. Specifically, MTI representatives will talk about our Manufacturing Services program- designed with you in mind.

The 2016 International Manufacturing Technology Show is going on right now (September 12-17, 2016 in Chicago, IL) and MTI is here! We’re in the North Building, B Hall (Fabricating & Lasers), Booth N-6014 and it’s great talking with colleagues in the manufacturing sector about our friction welding technologies. MTI representatives are here talking about how upgrading your controls package and service spare parts can benefit you.

The 2016 International Manufacturing Technology Show is going on right now (September 12-17, 2016 in Chicago, IL) and MTI is here! We’re in the North Building, B Hall (Fabricating & Lasers), Booth N-6014 and it’s great talking with colleagues in the manufacturing sector about our friction welding technologies. Specifically, MTI representatives are talking about our newest machine we’ve introduced: the double-ended rotary axle machine.

The 2016 International Manufacturing Technology Show is September 12-17, 2016 in Chicago, IL and MTI will be there! We’ll be in the North Building, B Hall (Fabricating & Lasers), Booth N-6014 where we’ll discuss our friction welding technologies and how they can improve your manufacturing processes. Specifically, MTI will be talking about Bi-Metallic Friction Welding and how it sets us apart in the joining industry.

The future of integration is now. What do I mean by that? I mean, we have seen many examples of how friction welding is seamlessly integrated into an automated manufacturing process. A number of our customers are already working with us and integrating friction welding technology into their production process. Based on their successes, it is the right time to take advantage of this innovative process that leads to (1) process repeatability, (2) improved cycle time, (3) increased production volume, and (4) cost savings.

Historically, many manufacturers have been reluctant to change from the familiar machine control systems they have used for decades over fears of incurring high upgrade costs. Despite the escalating price of maintaining a DOS system versus the affordable advantages of a modern Windows driven machine, concerns over the initial cost of switching to new and enhanced control systems have kept old ones in place well past their effectiveness.

In our second installment of Eyes of an Engineer, we introduce you to Jessica Miller, Dustin Bruntz, and Kaylee McConnell. They’ve all begun working as friction welding engineers with MTI within the past two years, though they’ve taken very different routes to their careers. Find out what they love about friction welding, how they got into it, and what they enjoy about being part of the MTI team.

MTI customers are helping us drive positive change in manufacturing every day. Our latest innovation — a double-ended rotary axle machine — is a perfect example.

Based on input from our customers, we’ve engineered a solution that uses advanced technology to increase efficiency, control and cost effectiveness in axle production.

As a manufacturer, you know there are many inherent risks in the production process. And one of the biggest is down-time. This is especially true for operators of critical equipment like friction welding machines. Whether your business is growing rapidly, you have production needs while your friction welding machine is being built, or your machine will be off line for scheduled maintenance, you can’t afford to slow down. That’s why MTI has developed a unique approach to keep your business up and running, around the clock.