Abstract: A Friction Stir Welding (FSW) approach can be used to join two structures, such as a plate to a base structure, or two portions of a wall of a structure such as a tubular structure (e.g., a pipe or vessel). According to various examples, FSW can be used for forming welds on an exterior-facing portion of a structure (e.g., externally), or on an interior-facing portion of a structure, such as within a confined environment. As an example, FSW can be performed within the confined environment using a compact spindle configuration as shown and described herein. FSW generally refers to a solid-phase processing technique where a tool is applied to a work piece, with rotation of the tool relative to the workpiece along with application of a forging force to drive a face of the tool into the workpiece to frictionally induce plastic deformation of material.

Abstract: Implementations are described herein that relate to manufacturing articles comprised of one or more metallic materials. In one or more examples, the one or more metallic materials can have a preformed shape that is inserted into the die. In one or more additional examples, the one or more metallic materials can include one or more powders or flakes disposed in the die. The material is then contacted within the die by a tool that moves in a rotational direction and in a vertical direction. The manufactured articles can have a shape that corresponds to the shape of the die.

Abstract: A tool assembly for friction extrusion can comprise a friction extrusion die. The friction extrusion die can include a distal face and a proximal end. The distal face can define at least one topographical ridge or groove feature to induce plasticization of a material in response to an axial force and a rotational force applied by the distal face to the material. The friction extrusion die can define a central passage to carry an extrudate of the material in a proximal direction in response to the applied axial and rotational forces. The proximal end can define a faceted cross-sectional profile to mate a with a corresponding receiving end of a tool holder. The faceted cross-sectional profile can be sized and shaped to receive the rotational force through engagement by the tool holder of respective faces defined by the faceted cross-sectional profile.