Abstract: An automated electric portable friction welding system is disclosed for friction welding a fixture onto a substrate, the welding system having a linear actuator received to produce a defined stroke within a tool housing and a rotary motor engaged to said linear actuator to slide therewith. A control module controls welding operations as a function of encoded instructions and the sensor data from the linear actuator and the rotary motor, whereby the control module affords both active control of the linear actuator and rotary motor, individually to performance parameter instructions, and in coordination through phases of the weld process in response to linear actuator operation sensors and motor operation sensors. Another feature of some embodiments of the present invention is a portable friction welding network and a method for supporting portable friction welding on the cloud.

Abstract: A multi-position clamp is disclosed for positioning and holding a portable friction welding tool adjacent a substrate for friction welding a plurality of fixtures in a precise pattern referenced from a fixed position on a substrate. The clamp has a clamp base temporarily securable at the fixed position on the substrate, a traveling mount comprising a tool mount for receiving said portable friction welding tool, and a connection to the clamp base allowing relative movement of the tool mount over the substrate. Index stops help install the plurality of fixtures in the pattern and an articulated fixture loading system allow positioning and loading successive fixtures without disengaging and removing said portable friction welding tool from connection with the clamp base.

Abstract: A multi-position clamp is disclosed for positioning and holding a portable friction welding tool adjacent a substrate for friction welding a plurality of fixtures in a precise pattern referenced from a fixed position on a substrate. The clamp has a clamp base temporarily securable at the fixed position on the substrate, a traveling mount comprising a tool mount for receiving said portable friction welding tool, and a connection to the clamp base allowing relative movement of the tool mount over the substrate. Index stops help install the plurality of fixtures in the pattern and an articulated fixture loading system allow positioning and loading successive fixtures without disengaging and removing said portable friction welding tool from connection with the clamp base.

Abstract: An automated system, method and tool for portable friction welding is disclosed for joining a rotatable workpiece to a substrate. A control system is disclosed receiving a start input to cause a motor to rapidly spin the workpiece and initiate a first thrust building cycle acting through an actuator to progressively force the spinning workpiece against the substrate. The materials at this intersection heat and plasticize and the actuator translates toward the substrate until the end of the desired actuator stroke operates to cut the motor off and to initiate and then hold a second axial thrust cycle on the actuator and there through to the interface of the workpiece and substrate. A reset input at the end of a cool off phase releases the thrust in the actuator.

Abstract: A method and buoyancy system are disclosed for facilitating diver directed underwater friction welding (also known as friction welding) operations. Various illustrative embodiments of the method, buoyancy system and combined portable friction welding system and buoyancy provisions are disclosed for improving ease of diver use in making underwater joints.