Abstract: Disclosed herein are systems, methods, and devices for repairing holes in weld seams created by bobbin friction stir welding tools. A hole may be created when a welding tool or, more specifically, a pin of the tool is removed or otherwise extracted from a weld seam created by the tool. The method may involve inserting a plug (e.g., a rivet) into the hole, reshaping the plug in the hole (e.g., riveting) thereby securing the plug in the component, and creating another weld seam through the plug thereby consuming the plug. In some embodiments, the hole may be reshaped prior to inserting the plug. For example, the hole may be drilled out and/or a countersink may be created on one or both ends of the hole. Furthermore, the plug may extend outside of the hole prior to its reshaping and, in some embodiments, even after reshaping.

Abstract: Disclosed herein are systems, methods, and devices for repairing holes in weld seams created by bobbin friction stir welding tools. A hole may be created when a welding tool or, more specifically, a pin of the tool is removed or otherwise extracted from a weld seam created by the tool. The method may involve inserting a plug (e.g., a rivet) into the hole, reshaping the plug in the hole (e.g., riveting) thereby securing the plug in the component, and creating another weld seam through the plug thereby consuming the plug. In some embodiments, the hole may be reshaped prior to inserting the plug. For example, the hole may be drilled out and/or a countersink may be created on one or both ends of the hole. Furthermore, the plug may extend outside of the hole prior to its reshaping and, in some embodiments, even after reshaping.

Abstract: Disclosed herein are systems, methods, and devices for repairing holes in weld seams created by bobbin friction stir welding tools. A hole may be created when a welding tool or, more specifically, a pin of the tool is removed or otherwise extracted from a weld seam created by the tool. The method may involve inserting a plug (e.g., a rivet) into the hole, reshaping the plug in the hole (e.g., riveting) thereby securing the plug in the component, and creating another weld seam through the plug thereby consuming the plug. In some embodiments, the hole may be reshaped prior to inserting the plug. For example, the hole may be drilled out and/or a countersink may be created on one or both ends of the hole. Furthermore, the plug may extend outside of the hole prior to its reshaping and, in some embodiments, even after reshaping.

Abstract: Disclosed herein are systems, methods, and devices for repairing holes in weld seams created by bobbin friction stir welding tools. A hole may be created when a welding tool or, more specifically, a pin of the tool is removed or otherwise extracted from a weld seam created by the tool. The method may involve inserting a plug (e.g., a rivet) into the hole, reshaping the plug in the hole (e.g., riveting) thereby securing the plug in the component, and creating another weld seam through the plug thereby consuming the plug. In some embodiments, the hole may be reshaped prior to inserting the plug. For example, the hole may be drilled out and/or a countersink may be created on one or both ends of the hole. Furthermore, the plug may extend outside of the hole prior to its reshaping and, in some embodiments, even after reshaping.

Abstract: Systems, methods, and devices are disclosed herein that repair and fill exit holes created by welding operations on vehicle components or parts. Methods may include inserting a plug into the exit hole in one or more vehicle parts, where the exit hole is created by the welding operation performed on the one or more vehicle parts. Methods may further include positioning a first pin on the plug such that the first pin is contacting an exposed surface of the plug, and rotating the first pin while contacting the exposed surface of the plug, where the rotating generates thermal energy based on a frictional force associated with the first pin and the plug. The methods may also include filling the exit hole by heating and plasticizing the plug via the thermal energy, and consolidating a material of the plug with the one or more vehicle parts.

Abstract: Systems, methods, and devices are disclosed herein that repair and fill exit holes created by welding operations on vehicle components or parts. Methods disclosed herein may include inserting a plug into an exit hole in one or more vehicle parts, where the exit hole is created by a welding operation performed on the one or more vehicle parts. Methods may also include positioning a shoulder member on the plug such that the shoulder member is contacting an exposed surface of the plug. Methods may further include rotating the shoulder member while contacting the exposed surface of the plug, the rotating generating thermal energy based on a frictional force associated with the shoulder member and the plug. Methods may also include filling the exit hole by heating and plasticizing the plug via the thermal energy, and consolidating a material of the plug with the one or more vehicle parts.

Abstract: A coldwork tool assembly including an outer housing and an inner housing in telescopic arrangement with each other and a retaining collar configured to accommodate a plurality of mandrel configurations. One of a plurality of various mandrels is removably coupled to the inner housing using the retaining collar to secure the mandrel to the inner housing as the inner housing moves between a contracted and an expanded position relative to the outer housing.

Abstract: Apparatus and methods for dampening vibration of a tool are provided. In one embodiment, a handle portion of a vibrating tool is inserted into a cavity of left and right side parts of a grip which is at least one of made of and lined with a vibration dampening material. The handle portion may be wrapped with a second vibration dampening material prior to being inserted within the grip. The casting of the handle portion of the vibrating tool may be reduced in order to avoid a size increase of the tool when the handle is enclosed within the cavity of the grip. In such manner, the tool may be more ergonomically feasible.

Abstract: A coldwork tool assembly including an outer housing and an inner housing in telescopic arrangement with each other and a retaining collar configured to accommodate a plurality of mandrel configurations. One of a plurality of various mandrels is removably coupled to the inner housing using the retaining collar to secure the mandrel to the inner housing as the inner housing moves between a contracted and an expanded position relative to the outer housing.

Abstract: A method and device for testing a substantially cylindrical tool having an axis is performed by imparting a testing torque to the cylindrical tool. The tool is clamped in a vise. The tool has a driven end including a shank and a working end in opposed relation along the axis. The vise is configured to clamp the tool to prevent rotation of the tool about the axis. The shank is clamped in a chuck. The chuck has a adapter defining a void configured to engagingly receive a socket drive shaft. A torque wrench having a lever arm and a socket driver shaft is engaged by insertion of the socket drive shaft into the void. A torque is imparted to the cylindrical tool about its axis by suitably imparting a force on the lever arm. The quantum of torque imparted is measured based upon operation of the torque wrench.

Abstract: An apparatus for forming features in a workpiece is provided. The apparatus includes a nosepiece that engages a boss of a template and guides a tool member therethrough. The nosepiece includes a housing and an adjustable member positioned at least partially in an interior space of the housing. The adjustable member defines radial apertures that hold locking members such as spherical bearings. The locking members are configured to contact a tapered portion of the inner surface of the housing so that as the adjustable member is adjusted from an unlocked position to a locked position, the locking members contact the tapered portion of the housing and are urged radially inward to retain the boss.

Abstract: An apparatus for forming features in a workpiece is provided. The apparatus includes a nosepiece that engages a boss of a template and guides a tool member therethrough. The nosepiece includes a housing and an adjustable member positioned at least partially in an interior space of the housing. The adjustable member defines radial apertures that hold locking members such as spherical bearings. The locking members are configured to contact a tapered portion of the inner surface of the housing so that as the adjustable member is adjusted from an unlocked position to a locked position, the locking members contact the tapered portion of the housing and are urged radially inward to retain the boss.

Abstract: An apparatus having a controllable dwell for drilling and or countersinking a hole in a workpiece is provided which generally comprises a feed mechanism, a retraction mechanism, and a dwell mechanism. The feed mechanism is configured to feed a spindle from a starting position to a predetermined feed limit during a feed cycle. The retraction mechanism is configured to retract the spindle from the feed limit to the starting position to complete the feed cycle. The dwell mechanism is in communication with the retraction mechanism and comprises a mechanical bias member that stores energy during at least a portion of the feed cycle, wherein the mechanical bias member releases at least a portion of the energy once the spindle reaches the feed limit. The retraction mechanism is only actuated once the spindle reaches the feed limit and the mechanical bias member releases at least a portion of the energy.

Abstract: An axial feed apparatus having an adjustable feed stop is provided. The axial feed apparatus generally comprises a power feed module having an adjustable stop mechanism engaged therewith, wherein the adjustable stop mechanism may comprise a spindle threadedly engaging the power feed module. An adjustable depth-controlling device is further included intermediate the spindle and the power feed module, which uses a series of calibrated graduations in communication with the spindle such that a rotational change in the engagement of the graduations moves the spindle by a predetermined axial distance and thereby adjust the position of the feed stop for the power feed module. Such a power feed module may be combined with a drill motor to produce a device capable of drilling/countersinking holes in a workpiece.

Abstract: The drill/countersink nosepiece assembly of the present invention permits the fabrication of a precise hole and countersink in a structural assembly workpiece in a single operation with the aid of a drill plate or other hole template. The small size of the nosepiece tip enables multiple holes to be closely spaced without interference between drill plate engagement slots. A close fit between the shaft of the rotating drill/countersink bit and the inner surface of the sleeve prevents the bit from wandering upon repeated or heavy use. The drill/countersink nosepiece comprises a combination drill/countersink bit to be received by a drill motor chuck, a bushing to be received by a fixed housing portion of the drill motor, a sleeve telescopically mounted within the bushing, a spring within the bushing to bias the sleeve forward, and fingers or other features at the end of the sleeve for engaging an alignment slot in a drill plate.