A solid-state joining process, friction stir welding creates extremely high-quality, high-strength joints with low distortion. MTI offers friction stir welding development and parts production through our manufacturing services.

Friction Stir Welding

MTI’s friction stir welding process development and part production is making a dramatic impact across many industries, including aerospace, defense, transportation, marine, and electronics. As a result, MTI have been granted a license for the manufacturing of friction stir welders (FSW) by the The Welding Institute, developers of the original patent.

Alternatively, please visit our linear friction welding (LFW) page if you require this service.

Advantages & Benefits

New solutions to old joining problems

Friction stir welding (FSW) allows us to continually identify new joining applications for extrusions, castings, plate, and sheet for customers ranging from railcars to aerospace. Our skilled MTI team is knowledgeable in the materials best suited for the process and can offer solutions to improve product performance, quality, and weld development.

Virtually defect-free bonding

As a solid-state process, friction stir welding eliminates many of the defects associated with conventional fusion welding techniques such as shrinkage, solidification cracking, and porosity. The bond between the two pieces is made solely of the original material, giving it similar strength, bending, and fatigue characteristics of the parent material.

Dual head capability for faster panel welding

Our large panel production machine is equipped with dual upper and lower weld heads for extrusions or panels that require a top and bottom welded assembly. Welding a large panel or part assembly on both sides saves time and money.

Superior mechanical characteristics

Friction stir welding produces a weld with high weld strength and toughness, plus a fine grain structure that resists fatigue stress. Due to the low heat and small heat-affected zone, there is minimal distortion of the joined parts, reducing the costs associated with preparing the part for subsequent use.

Limitless panel length and width

The flexibility of our friction stir welding process means we can accommodate the welding of large parts. Our in-house equipment can produce friction stir welds up to 55 feet long. This also allows the capability to join aluminium sheets produced at the mill, thereby increasing sheet widths while maintaining plate thickness tolerances.

Join dissimilar alloys

Friction stir welding (FSW) may be used to weld dissimilar alloys – even combinations not compatible with conventional welding methods.

Joint Geometries


Butt Laminate


Lap Laminate

Butt Both Sides



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