Mazak MegaStir Friction Stir Welding technology is said to provide “a versatile joining solution for the mechanized welding of dissimilar metals without toxic fumes and molten spatter.” (Photo courtesy Mazak Corporation)
Mazak MegaStir will highlight the benefits of the process by pairing its FSW technology with a Mazak VC-Ez 16 CNC Turning Center at an upcoming event.
FLORENCE, Ky.—The benefits of high-speed friction stir welding (FSW) will be on display when Mazak MegaStir highlights the advantages of its technology at Mazak’s biennial DISCOVER 2025 event in October.
Mazak MegaStir is planning to show visitors how friction stir welding provides “a versatile joining solution for the mechanized welding of dissimilar metals without toxic fumes and molten spatter.” It will do so by pairing Mazak MegaStir FSW technology with a Mazak VC-Ez 16 CNC Turning Center, fashioning a system that provides lower setup costs and requires less training than traditional fusion welding, according to a release from Mazak.
Instead of current and voltage used in arc welding, friction stir welding joins metals with heat produced by the rotational downforce and friction generated by a cylindrical shouldered tool and profiled pin. Heat generated between the welding tool and workpiece plasticizes the materials before they reach their melting points, forging a joint that is “nearly always superior to conventional fusion-welded methods,” the release stated.
Friction stir welding minimizes the heat-affected zone (HAZ), which is typically the weakest part of a weld. Instead, it 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,” Mazak stated in the release. “Residual stresses are also lower, reducing distortion and improving overall structural integrity. The process does not require filler wire or shielding gas and joins in a single pass and at all positions and orientations.”
Designed and built in Kentucky, the VC-Ez 16 is optimized for fast, easy installation and simple operation that is said to provide “Mazak performance and reliability to shops of any size.” Heavy base, column, and headstock castings are designed for high-speed, high-torque applications. In addition, a Thermal Displacement Control function monitors and reacts to environmental and internal temperature fluctuations to maintain stable machining accuracy for long periods of time, the company said.
The machine features MAZATROL SmoothEz CNC, which gives shops MAZATROL G-code and conversational programming capabilities, and FSW software. The software, available through Mazak’s MAZATROL Smooth CNC, allows real-time monitoring of FSW’s three main processes—plunging, traversing, and extracting, the company said.
The DISCOVER 2025 event will take place October 6-10 at the Mazak North American headquarters in Florence.
The event will also highlight Mazak MegaStir’s patented, ultra-hard diamond tipped FSW pin tools, designed specifically for joining aluminum alloys and higher performance, longer tool life, and superior weld quality. Reported to have the strength of polycrystalline diamond, the tools are said to provide effective thermal conductivity for improved weld surface finishes and allow for higher spindle speeds that boost FSW productivity rates.
Key benefits are reported to 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, the release said.