Abstract: A panel structure including structural members connected together by a friction stir welding process. The structure includes a plurality of cross members, wherein each of the plurality of cross members is parallel to the other cross members in the plurality of cross members and wherein at least one of the plurality of cross members. An end cap member is positioned orthogonally to each of the plurality of cross members and connected to an end of each of the plurality of cross members. The end cap member includes a plurality of flanges, and each of the plurality of flanges includes a chamfered portion that fits within an opening at the end of one of the plurality of cross members.

Abstract: A panel structure including structural members connected together by a friction stir welding process. The structure includes a plurality of cross members, wherein each of the plurality of cross members is parallel to the other cross members in the plurality of cross members and wherein at least one of the plurality of cross members. An end cap member is positioned orthogonally to each of the plurality of cross members and connected to an end of each of the plurality of cross members. The end cap member includes a plurality of flanges, and each of the plurality of flanges includes a chamfered portion that fits within an opening at the end of one of the plurality of cross members.

Abstract: A panel structure includes panel members that may be connected together using friction stir welding, Each of the panel members includes a first plate, a second plate substantially in parallel to said first plate, and at least one webbing member connecting the first plate and the second plate. The first plate of the first panel member includes a flange positioned in abutment with a flange located on the first plate of the second panel member. The flange of the first panel member includes a projection and the flange of the second panel member includes a groove. The panel members are connected so that the projection is engaged with the groove to thereby resist relative lateral movement that would separate the panel members.

Abstract: A self alignment structure for joining extruded members. The self-aligning structure includes one or more decking members including an upper panel and a lower panel connected by webbing members. One side of the decking member has a void space between the upper panel and lower panel and another side the decking member may have a vertical webbing member between the upper panel and the lower panel. The self aligning structure further includes an upper shelf and lower shelf, each shelf extending horizontally relative to the vertical webbing member. The shelves being operable to align a neighboring decking member, forming abutment joints in preparation for a friction stir welding process.

Abstract: A panel structure includes panel members that may be connected together using friction stir welding, Each of the panel members includes a first plate, a second plate substantially in parallel to said first plate, and at least one webbing member connecting the first plate and the second plate. The first plate of the first panel member includes a flange positioned in abutment with a flange located on the first plate of the second panel member. The flange of the first panel member includes a projection and the flange of the second panel member includes a groove. The panel members are connected so that the projection is engaged with the groove to thereby resist relative lateral movement that would separate the panel members.

Abstract: A self alignment structure for applications joining extruded members is provided. The self-aligning structure may comprise one or more bridge decking members including an upper panel and a lower panel connected by webbing members therebetween. One side of the bridge decking member have a void space between the upper panel and lower panel and an other side the decking member may have a vertical webbing member between the upper panel and the lower panel. The self aligning structure may further include an upper shelf and lower shelf, each extending horizontally away from the vertical webbing member, operable to align a neighboring decking member, forming abutment joints in preparation for the application of a joining application, such as a friction stir welding tool.