Mazak’s milling machines expand multitasking capabilities with friction stir welding tooling
Mazak’s milling machines expand multitasking capabilities with friction stir welding tooling
As a pioneer in friction stir welding (FSW) technology, Mazak MegaStir showcased its patented high-speed Instrumented Tool Holder (ITH) for friction stir welding (FSW) during Fabtech 2025. Mazak MegaStir takes the process to the next level with its fast-moving ITH that further boosts joint strength and provides practically zero part distortion. The tool holder is used in Mazak HYBRID Multi-Tasking machine operations that combine subtractive processes with that of FSW assembly/joining. This hybrid platform provides the ability to join assembly components on the same machine with the same operator and consolidates factory floor footprints while decreasing capital expenditures.
As a pioneer in friction stir welding (FSW) technology, Mazak MegaStir showcased its patented high-speed Instrumented Tool Holder (ITH) for friction stir welding (FSW) during Fabtech 2025. One of the capabilities is that the tool holder can be used in Mazak HYBRID Multi-Tasking machine operations that combine subtractive processes with that of FSW assembly/joining.
"This hybrid platform provides the ability to join assembly components on the same machine with the same operator and consolidates factory floor footprints while decreasing capital expenditures," said Dale Fleck, general manager, Mazak MegaStir.
Mazak MegaStir Instrumented Tool Holder is pulled – via a normal tool change cycle – from the tool magazine of a Mazak vertical or horizontal machining center to perform FSW operations.">By adding friction stir welding to milling machines as a tooling change out, Fleck says it "adds efficiency to the machine. We also have rapid operation, so we can go from operation one to 'op' two and to 'op' three with just a quick tool change out. It's really an all -in -one solution."
Mazak MegaStir's term for this multitasking concept is called "on-machine assembly," he said. "On-machine assembly combines additive with current technologies that are available, subtraction and joining. So, most Mazak milling machines are designed for subtraction. We remove metal through the milling process. The next step would be to take a second part, whether it's a complex machine part or just sheet metal, and join that to the first part. And from doing that, we join it using stir welding, the best joining technology possible."
Mazak MegaStir takes the process to the next level with its fast-moving ITH that utilizes wireless Bluetooth communication with the tool holder that sits in the tool crib. "If you're interested in improving your throughput, improving your efficiency, friction stir welding at 10 meters a minute, which is the fastest joining process that you can do, look into Mazak," he said.
For the Mazak MegaStir process, the FSW Instrumented Tool Holder is pulled – via a normal tool change cycle – from the tool magazine of a Mazak vertical or horizontal machining center to perform FSW operations. The ITH collects temperature, Z-axis load data, and other information to enable operators to manage the FSW process. FSW software available through Mazak's MAZATROL Smooth CNC allows real-time monitoring of FSW's three main processes – plunging, traversing, and extracting.
FSW minimizes the heat-affected zone (HAZ), which is typically the weakest part of a weld. Instead of an HAZ, FSW creates a thermo-mechanical zone that retains the base metal's strength because of its refined grain structure. This results in a stronger, more reliable weld. Residual stresses are also lower, reducing distortion and improving overall structural integrity.
Mazak MegaStir-patented ultra-harddiamond tipped FSW pin tools.">
Attendees also experienced Mazak MegaStir-patented ultra-hard diamond tipped FSW pin tools designed specifically for joining aluminum alloys and deliver higher performance, longer tool life and superior weld quality. With the strength of polycrystalline diamond, the tools provide effective thermal conductivity for improved weld surface finishes and allow for higher spindle speeds that boost FSW productivity rates.
Key benefits include up to 150 times more tool life, lower operating costs and shorter return on investment (ROI). The tips are available in standard and customized versions and are thermocouple-ready, Fleck said.
