Abstract: A friction stir welding tool includes that a body and a pin formed integrally with the body at one end thereof. The body and pin further include a first material and a second material; wherein the first material further includes a molybdenum-based refractory alloy; and wherein the second material further includes hafnium, lanthanum, carbon, titanium, zirconium, or combinations thereof.

Abstract: A method of inertia friction welding a superalloy substrate, the method including: rotating and forcing a deposit material (110) against the superalloy substrate (100); plastically deforming at least one of the deposit material (110) and the superalloy substrate (100) to form a weld joining the deposit material (110) to the superalloy substrate (100), thereby forming an assembly; and heat-treating the assembly. Heat-treating includes: a post-weld intermediate stress-relief (ISR) treatment; a solutionizing treatment; and a precipitation hardening heat treatment.

Abstract: A method of inertia friction welding a superalloy substrate, the method including: rotating and forcing a deposit material (110) against the superalloy substrate (100); plastically deforming at least one of the deposit material (110) and the superalloy substrate (100) to form a weld joining the deposit material (110) to the superalloy substrate (100), thereby forming an assembly; and heat-treating the assembly. Heat-treating includes: a post-weld intermediate stress-relief (ISR) treatment; a solutionizing treatment; and a precipitation hardening heat treatment.

Abstract: The apparatus (50) includes a friction stir welding tool (100), a local clamping means (200), and an interface (300) that joins the tool (100) and the local clamping means (200). The local clamping means (200) is in close proximity to the at least one sidewall (130) of the tool (100) and has a housing (210) and a plurality of contact devices (220). The local clamping means (200) transfers a clamping force to the first and the second components (C1, C2) and holds them firmly in place during welding. The local clamping means (200) includes a plurality of contact devices (220) that may take the form of casters, rollers (222), and ball bearings (224). The location of the contact devices (220) is significant as external clamping is greatly reduced, and often eliminated, as the contact devices (220) are brought into close proximity to the area of the weld.

Abstract: A friction stir welding (FSW) travel axis load control method and apparatus for controlling a travel axis load applied to a FSW setup during the joining of workpieces by FSW. The method and apparatus recognize that controlling certain attributes of a friction stir welding plasticized region are key to controlling the quality of the resulting weld. This invention controls any of a number of qualities associated with the plasticized region thereby producing welds having improved mechanical and aesthetic properties, as well as extending the life of the FSW tool. The method and apparatus may control the FSW process to obtain a predetermined optimum size of a heat affected zone. The plasticized region may be monitored in a number of ways including, but not limited to, force on the tool, torque applied to the tool, workpiece temperature, plasticized region physical dimension, as well as changing surface characteristics such as color and reflectivity.

Abstract: The present invention provides a friction stir welding apparatus and associated thermal management systems and methods for joining one or more similar or dissimilar materials forming a workpiece along a joint to be welded. The friction stir welding apparatus includes a pin tool apparatus selectively disposed adjacent to and in direct contact with a first surface of the workpiece along the joint to be welded and a heating member disposed adjacent to a second surface of the workpiece along the joint to be welded, the heating member operable for controllably heating at least a portion of the workpiece adjacent to the joint to be welded. The friction stir welding apparatus also includes an annular spindle having an interior portion and an axis, the interior portion of the annular spindle at least partially defining one or more cooling channels, the one or more cooling channels operable for containing a cooling fluid.

Abstract: An apparatus is provided for joining electrically conductive materials by friction stir welding. The apparatus includes a shaft portion for being received by a rotation imparting apparatus, and a second end having a cut-away portion configured for deflecting plasticized material during friction stir welding. A pilot formed of a material harder than the electrically conductive material extends from the second end. The pilot is configured and dimensioned for friction stir welding electrically conductive members together.