Mazak buys MegaStir friction-stir welding company
Photo courtesy of MegaStir

Mazak buys MegaStir friction-stir welding company

Machine tool manufacturer looks to expand its forming/joining options for future machining centers.


Florence, Kentucky – Mazak Corp. is looking to add joining and forming applications to its multi-tasking machining center lineup with the purchase of MegaStir, a friction-stir welding (FSW) tool and technology company in Provo, Utah.

The Mazak MegaStir will provide further system advancements and evolve into an FSW technology center. A resident FSW machine in Provo as well as in other Mazak Technology Centers will provide customers the potential for real manufacturing solutions in a Done in One capacity.

Mazak collaborated with MegaStir on the development of the Mazak VTC-800 FSW, a vertical 5-axis machining center that led to the Mazak VTC-300C FSW shown at the International Manufacturing Technology Show (IMTS) in Chicago.

Designed and manufactured in Kentucky, the VTC-300C FSW features Mazak’s MAZATROL SmoothG CNC, a powerful 40-taper spindle, full traveling-column design, and a fixed table for the machining of extremely long and heavy workpieces (or multiple work-holding fixtures).

The FSW package adds friction welding to the spindle via a tool holder. Closed-loop FSW process control and FSW programming software enhance the speed and capability of the process. Mazak President Dan Janka says, “Our goal is to continuously explore and develop new technologies, processes. and product innovation that will keep our customers productive, competitive, and profitable. The various Mazak FSW machines are perfect examples of that.”

Since 2002, MegaStir has developed FSW tool material innovations and applications. Designed for endurance and quality welding, MegaStir tools consistently produce top quality, high strength welds in a single pass.

Dale Fleck will head up operations as the general manager of the new Mazak MegaStir and says that all those at MegaStir are thrilled to now be part of the Mazak team.

FSW is a solid-sate joining process that uses frictional heat and forging pressure to create full-penetration, defect-free welded joints with greater strength than conventional welding methods. A non-consumable tool joins two metal plates without melting the workpiece. Commonly considered a forging process, FSW is well-suited for joining alloys with low melting points, including aluminum, copper, and brass.