Steel Fabrications for Aerospace and Military

J & J is manufacturing four large steel fabrications for a Rotary Friction Welding Machine that will be used in building critical engine components for the United States military.

Rotary friction welding is a process in which one part is turned at a high rate of speed and is forced against another part that is held stationary. The resulting friction heats the parts to a temperature at which they forge together. This advanced welding technique produces a stronger bond than conventional welding. It also creates a significant cost savings because two different metals can be welded together, allowing for the more expensive metals to only be used in critical areas rather than throughout the entire component. Additionally, rotary friction welding is quick, inexpensive, does not require any consumables, and due to its solid-state nature, allows the parts being joined to retain properties close to those of the parent materials.

The fabrications that J & J is building include a base and base extension, along with right and left hand platens. Three of the four parts weigh over 100,000 pounds, with the largest one at 140,000 pounds. In total, these four components will require over 2,000 labor hours to complete. The capacity to handle parts of this mammoth size sets us apart from other steel fabricators. Our competitive edge lies in our advanced equipment and experienced work force. Only a very few metal fabricators in the United States are able to complete a project of this size and complexity.

All of the parts are in-process at this time, with expected completion dates in April and May.

In the first two photos, you see the 112,000# base that measures 54” x 110” and 241”.

Photos 3 and 4 are the side and top views of the right hand platen that is 54” x 136” x 137”.

The last photo shows the larger of the two platens in its early stages. It will be 64” x 134” x 136”.

steel fabrication for US Military

112,000 pound steel base

Welding a heavy steel base

Welding of a heavy steel base

Steel Plate Platen

Top View of Platen

Steel Plate Fabrication

Side View of Platen

Platen steel fabrication for the military

In-Process Steel Weldment

Welding Large Steel Fabrications

Welders at J & J Burning and Fabricating have been busy lately with several intense jobs for industries such as Mining, Aerospace and Plastics. In this photo, we are working on a Ramp Frame for the Mining Industry that requires 175 hours of welding.

Welding of a steel fabrication for the Mining Industry
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The welding process, in various forms, has been around since ancient times. The following is a brief history of welding from the Middle Ages through the 19th Century found at

History of Welding
Middle Ages
Welding can trace its historic development back to ancient times. The earliest examples come from the Bronze Age. Small gold circular boxes were made by pressure welding lap joints together. It is estimated that these boxes were made more than 2000 years ago. During the Iron Age the Egyptians and people in the eastern Mediterranean area learned to weld pieces of iron together. Many tools were found which were made approximately 1000 B.C.

During the Middle Ages, the art of blacksmithing was developed and many items of iron were produced which were welded by hammering. It was not until the 19th century that welding, as we know it today was invented.


Edmund Davy of England is credited with the discovery of acetylene in 1836. The production of an arc between two carbon electrodes using a battery is credited to Sir Humphry Davy in 1800. In the mid-nineteenth century, the electric generator was invented and arc lighting became popular. During the late 1800s, gas welding and cutting was developed. Arc welding with the carbon arc and metal arc was developed and resistance welding became a practical joining process.


Auguste De Meritens, working in the Cabot Laboratory in France, used the heat of an arc for joining lead plates for storage batteries in the year 1881. It was his pupil, a Russian, Nikolai N. Benardos, working in the French laboratory, who was granted a patent for welding. He, with a fellow Russian, Stanislaus Olszewski, secured a British patent in 1885 and an American patent in 1887. The patents show an early electrode holder. This was the beginning of carbon arc welding. Bernardos’ efforts were restricted to carbon arc welding, although he was able to weld iron as well as lead. Carbon arc welding became popular during the late 1890s and early 1900s.


In 1890, C.L. Coffin of Detroit was awarded the first U.S. patent for an arc welding process using a metal electrode. This was the first record of the metal melted from the electrode carried across the arc to deposit filler metal in the joint to make a weld. About the same time, N.G. Slavianoff, a Russian, presented the same idea of transferring metal across an arc, but to cast metal in a mold.

SOURCE: Hobart Institute of Welding Technology

Stainless Steel Machines

We are currently fabricating nine sets of bridges and bases that combine to become components of stainless steel Blow-Fill-Seal machines. These machines are used to produce small and large volume sterile liquid-filled containers used by the pharmaceutical, health care, and food industries. . This safe and sterile technology is considered superior by various regulatory agencies, including the United States Food and Drug Administration. A container is formed, filled and sealed in a continuous process, without human intervention, in a sterile enclosed area inside a machine. Examples of the containers that can be produced are: IV bottles, contact lens solution bottles, and squeezable beverage containers.

To fabricate these parts, J & J Burning uses prime, mill-certified 304 stainless steel plate in thicknesses ranging from 3/8” – 1 1/4”. Each set requires over 260 labor hours to manufacture. To ensure dimensional stability when building stainless steel fabrications, our welders employ pulse-puddle arc welding and all parts go through vibratory stress relief. These added processes eliminate warping and distortion and allow the parts to remain within a tight tolerance. For cosmetic enhancement, the parts are blasted with glass beads prior to machining to produce a smooth, bright finish.

These pictures show the bases and bridges in-process at J & J, along with the finished machine and a diagram of how it works.

stainless steel bases

stainless steel bases in-process

stainless steel bases and bridges in-process

stainless steel bases and bridges in-process

Stainless Steel Machine

complete machine and sample containers

how it works

how it works