Abstract: A method is disclosed for controlling the magnitude and location of the weld notch which results from inertia welding of certain materials, such as superalloys. By controlling the size and geometry of the articles being joined a curved weld zone will result and the material expelled from the weld zone which produces the weld notch will be directed in a fashion which moves the weld notch outside of the original diameter of the articles being joined. The resultant welded article consisting of a larger portion and a smaller portion can be machined to the size of the smaller portion without any residual weld notch.

Abstract: Geometries are described for joining superalloy articles by inertia welding. First and second hollow superalloy articles are joined wherein the first article has an inside and an outside diameter which are less than the inside and outside diameter of the second article. This produces a staggered joint geometry which results in curved "S" shaped weld zone and beneficial control of the residual weld notch.