Mazak MegaStir Spotlights the Benefits of High-speed Friction Stir Welding at FABTECH 2025

Jul/22/2025
  • Company

FLORENCE, Ky. July 22, 2025 – Mazak MegaStir will showcase its patented high-speed Instrumented Tool Holder (ITH) for friction stir welding (FSW) during FABTECH 2025 in the Mazak Optonics booth A3502. As a pioneer in FSW technology, 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 Instrumented 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.

For the Mazak MegaStir process, an 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.

FABTECH attendees will also experience 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.