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LIFT: Lightweight Innovations for Tomorrow

LIFT: Lightweight Innovations for Tomorrow
Home // Newsletter // Bond Technologies Innovates in Lightweighting and Welding

Bond Technologies Innovates in Lightweighting and Welding

February 2, 2017

FSW Welding machine

Extensive knowledge of joining technologies and capabilities is one of the many areas of expertise offered by LIFT SME member Bond Technologies, Inc. Headquartered in Elkhart, Ind., Bond is one of the few companies in the world whose core business is the development, design and building of friction stir welding machines.

That knowledge is important in the lightweighting world, largely because friction stir welding is ideal for joining aluminum and magnesium materials, said CEO Tim Haynie, who has more than 15 years of experience in the industry as a solutions provider for engineering and special projects.

“We look at the needs and the challenges that our customers are likely to have in the marketplace,” Haynie said. “We’re not afraid to take on one-off projects and that is the mindset that has helped to build our company.”

The benefits of joining aluminum or magnesium with friction stir welding are many, according to Haynie. Such joining offers low distortion, has minimal heat input and is very energy-efficient. It requires little post-processing and no shielding gas or fillers, and results in a very fine grain structure that is highly resistant to corrosion. Excellent fatigue properties can also be achieved.

FSW Weld HeadThe process of friction stir welding has been around for about two decades, Haynie said, but in recent years has become more accepted by additional industries, notably automotive. Bond Technologies works with customers in many transportation industries, such as launch vehicles, high speed rail and shipbuilding. That interest from automotive customers has been piqued in recent years with the inclusion of more aluminum alloys in some passenger vehicles.

Friction stir welding machines are used for both research and development purposes and in production applications such as electronics cooling in the automotive industry, fuel tanks, sputtering discs, axle assemblies, half-shafts, conductor rails, coil joining, deck plate joining, and other production items in various markets. Bond’s professionals have adapted what they have learned to influence process control over such a broad variety of applications.

Bond recently began to increase its complex contour welding work in a 3D space as a way to tackle difficult jobs that many other solution providers won’t touch, Haynie said. While friction stir welding machines are the company’s core business, Bond Technologies also completes custom machine and prototype machine development solutions. Recently it developed a machine capable of friction extrusion, which involves the use of frictional heat as a way to produce metals with fine grain structure to improve fatigue performance and reduce corrosion.

“We have built a reputation of very accurate machine building and really just being a jack-of-all-trades,” said Haynie, whose company employs 11 professionals, many of whom have worked with him for nearly two decades. “We are routinely selected by research institutions and universities to provide one-of-a-kind equipment solutions with unique mechanical or control system requirements.”

Bond Technologies also employs a full engineering staff handling both mechanical design and controls. With over 50 years of combined experience, its professionals can design and supply machines and fixtures for small production parts to large systems used in the aerospace, ship building and railcar industries.

Learn more by visiting or call 574-327-6730.