Abstract: An apparatus and method for removing weld flash from a structural assembly are provided. The apparatus generally includes a tool with a head that defines an edge and first and second opposite surfaces disposed at an angle converging toward the edge. A shaft, which extends from the first surface of the head, is configured to be engaged to a shaft holder of an actuation device so that the head extends from the actuation device and is configured to lift the flash from a surface of the assembly as the tool is moved in a path along a surface of the assembly with the edge contacting the flash.

Abstract: An assembly for positioning a structural assembly for friction stir welding, and a system and method for friction stir welding the structural assembly are provided. The assembly includes a substrate defining a recessed pattern therein, and at least one structural member positioned within the recessed pattern to at least partially secure the structural member therein. The structural member is positioned adjacent to the substrate and within the recessed pattern such that the substrate and structural member are formed of materials capable of being friction stir welded together.

Abstract: An assembly for positioning a structural assembly for friction stir welding, and a system and method for friction stir welding the structural assembly are provided. The assembly includes a substrate defining a recessed pattern therein, and at least one structural member positioned within the recessed pattern to at least partially secure the structural member therein. The structural member is positioned adjacent to the substrate and within the recessed pattern such that the substrate and structural member are formed of materials capable of being friction stir welded together.

Abstract: A method of making a tailored blank comprising the following steps: (a) friction welding first and second structural members together at a substantially right angle with respect to each other to form an intersection comprising a first joining surface formed by adjoining bottom faces of the first and second structural members, and a second joining surface formed by an angled face of the first structural member that is disposed at a first oblique angle relative to the bottom face of the first structural member; (b) friction welding the first joining surface of the intersection to a first portion of a surface of a base member; and (c) concurrently linear friction welding first and second joining surfaces of a third structural member to the second joining surface of the intersection and to a second portion of the surface of the base member respectively.

Abstract: An assembly for positioning a structural assembly for friction stir welding, and a system and method for friction stir welding the structural assembly are provided. The assembly includes a substrate defining a recessed pattern therein, and at least one structural member positioned within the recessed pattern to at least partially secure the structural member therein. The structural member is positioned adjacent to the substrate and within the recessed pattern such that the substrate and structural member are formed of materials capable of being friction stir welded together.

Abstract: An assembly may include at least two structures having angled edges disposed adjacent to one another forming a first gap between the at least two structures. A plurality of angled joining members may be linear friction welded adjacent to one another between the adjacent angled edges of the at least two structures in the first gap. A second gap may be disposed between the plurality of linear friction welded angled joining members. At least one hole may be disposed at a location of the second gap. The at least one hole may extend into and between adjacent edges of the welded angled joining members, and may extend into and between the adjacent angled edges of the at least two structures. A plug member may be rotary friction welded at least partially into the at least one hole.

Abstract: The present application is directed to a process for forming a machined part. The process comprises providing a substrate and depositing a rough part on the substrate. One or more sacrificial supports are deposited adjacent to the rough part on the substrate. All or a portion of the one or more sacrificial supports and a portion of the rough part are removed. Additional embodiments are directed to aircraft part assemblies, and aircraft parts made by the above process.

Abstract: An assembly may include at least two structures having angled edges disposed adjacent to one another forming a first gap between the at least two structures. A plurality of angled joining members may be linear friction welded adjacent to one another between the adjacent angled edges of the at least two structures in the first gap. A second gap may be disposed between the plurality of linear friction welded angled joining members. At least one hole may be disposed at a location of the second gap. The at least one hole may extend into and between adjacent edges of the welded angled joining members, and may extend into and between the adjacent angled edges of the at least two structures. A plug member may be rotary friction welded at least partially into the at least one hole.

Abstract: Under one step of one embodiment of a solid state method for joining structures, angled edges of at least two structures are disposed adjacent to one another. In another step, a plurality of angled joining members are disposed adjacent to one another between the adjacent angled edges of the at least two structures. In still another step, the angled joining members are welded between the adjacent angled edges of the at least two structures. In yet another step, at least one hole is formed into and extended between adjacent edges of the welded angled joining members. In an additional step, a plug member is forced at least partially into the at least one hole.

Abstract: Under one step of one embodiment of a solid state method for joining structures, angled edges of at least two structures are disposed adjacent to one another. In another step, a plurality of angled joining members are disposed adjacent to one another between the adjacent angled edges of the at least two structures. In still another step, the angled joining members are welded between the adjacent angled edges of the at least two structures. In yet another step, at least one hole is formed into and extended between adjacent edges of the welded angled joining members. In an additional step, a plug member is forced at least partially into the at least one hole.

Abstract: An apparatus and method for removing weld flash from a structural assembly are provided. The apparatus generally includes a tool with a head that defines an edge and first and second opposite surfaces disposed at an angle converging toward the edge. A shaft, which extends from the first surface of the head, is configured to be engaged to a shaft holder of an actuation device so that the head extends from the actuation device and is configured to lift the flash from a surface of the assembly as the tool is moved in a path along a surface of the assembly with the edge contacting the flash.

Abstract: A method of making tailored blanks in accordance with one embodiment comprises the steps of friction welding a first joining surface of a first structural member having a substantially non-rectangular parallelogram profile to a first portion of a joining surface of a substrate; and thereafter concurrently linear friction welding first and second joining surfaces of a second structural member having a substantially non-rectangular parallelogram profile to a second portion of the surface of the substrate and to a second joining surface of the first structural member respectively. The first and second portions of the surface of the substrate are adjacent. Two or more structural members having a substantially non-rectangular parallelogram profile can be linear friction welded in succession to the substrate and to each other, thereby building a structural assembly having a long flange or other long feature of a desired length.