Abstract: A deposition friction stir weld process of joining work pieces includes placing a filler material on and about a joint line formed by butting a first work piece surface against a second work piece surface; and frictionally heating the filler material to soften the filler material and portions of the first and second work piece surfaces in thermal contact with the filler material and form a weld between the first and second work pieces, wherein frictionally heating is at a temperature below a melting point of the filler material and the first and second workpiece surfaces. Also disclosed herein are friction stir welding assemblies for providing the deposition friction stir weld as well as processes for depositing filler material and contouring a workpiece surface.

Abstract: A hybrid metal forming system includes a die cavity defined by a first die and a second die and a press adapted to apply a static pressure over the first die to deform a workpiece against the second die. The hybrid forming system also includes a dynamic loading system coupled to and positioned between, the press and the die cavity.

Abstract: A method for thermal forming includes determining a process window for initiating cooling, locally heating at least one region on a specimen to achieve a pre-selected geometry deformation, initiating active cooling of the heated region within the process window to control at least one material property of the specimen at the heated region and actively cooling the heated region to a pre-selected temperature. A system for thermal forming includes a thermal source for heating the region on the specimen to achieve a pre-selected geometry deformation, an active cooling module for cooling the region to a pre-selected temperature and a control module to control at least one of the thermal source and active cooling module in accordance with a process window to initiate active cooling to control at least one material property of the specimen at the heated region. The process window has an upper time limit for initiating cooling.

Abstract: Briefly, in accordance with one or more embodiments, one or more thermal forming treatments may be predicted to achieve a desired shape and/or microstructure in a workpiece.

Abstract: A hybrid metal forming system includes a die cavity defined by a first die and a second die and a press adapted to apply a static pressure over the first die to deform a workpiece against the second die. The hybrid forming system also includes a dynamic loading system coupled to and positioned between, the press and the die cavity.