Abstract: In one aspect of the present disclosure, a friction stir processing tip is provided for a friction stir processing device. The friction stir processing tip includes a body having a central longitudinal axis, a friction stir processing portion of the body, and a connecting portion of the body configured to connect to a tip holder of the friction stir processing device. The connecting portion includes splines configured to receive a torque from the tip holder for rotating the body about the central longitudinal axis.

Abstract: A friction stir processing (FSP) tool includes a pin having a pin body and a rotational axis. The pin is configured to rotate about the rotational axis in a rotational direction. The pin has a radial protrusion protruding radially from the pin body, and the radial protrusion has a working surface oriented in the rotational direction with a depth in a radial direction relative to the rotational axis.

Abstract: In one aspect of the present disclosure, a friction stir processing tip is provided for a friction stir processing device. The friction stir processing tip includes a body having a central longitudinal axis, a friction stir processing portion of the body, and a connecting portion of the body configured to connect to a tip holder of the friction stir processing device. The connecting portion includes splines configured to receive a torque from the tip holder for rotating the body about the central longitudinal axis.

Abstract: A system and method for providing a folding load bearing hard tonneau cover, wherein each folding section is constructed using friction stir welds for strength, stiffness and visual appeal, wherein edge extrusions may include an integral attachment track which is capable of sustaining high tie down loads, wherein a spring loaded latching system has the strength to react the moments generated by heavy loads on top of the tonneau cover, wherein installation does not require modification to the bed but instead uses a 2 bolt attachment system, and wherein the tonneau cover may carry heavy loads on top that are easy to secure, and wherein a custom carrying frame is easily attachable to the tonneau cover to enable large and heavy loads, even some that are longer than the pick-up bed, to be carried on the tonneau cover while enabling use of the pick-up bed for other cargo.

Abstract: A system and method for providing a folding load bearing hard tonneau cover, wherein each folding section is constructed using friction stir welds for strength, stiffness and visual appeal, wherein edge extrusions may include an integral attachment track which is capable of sustaining high tie down loads, wherein a spring loaded latching system has the strength to react the moments generated by heavy loads on top of the tonneau cover, wherein installation does not require modification to the bed but instead uses a 2 bolt attachment system, and wherein the tonneau cover may carry heavy loads on top that are easy to secure, and wherein a custom carrying frame is easily attachable to the tonneau cover to enable large and heavy loads, even some that are longer than the pick-up bed, to be carried on the tonneau cover while enabling use of the pick-up bed for other cargo.

Abstract: A system and method for providing a folding load bearing hard tonneau cover, wherein each folding section is constructed using friction stir welds for strength, stiffness and visual appeal, wherein edge extrusions may include an integral attachment track which is capable of sustaining high tie down loads, wherein a spring loaded latching system has the strength to react the moments generated by heavy loads on top of the tonneau cover, wherein installation does not require modification to the bed but instead uses a 2 bolt attachment system, and wherein the tonneau cover may carry heavy loads on top that are easy to secure, and wherein a custom carrying frame is easily attachable to the tonneau cover to enable large and heavy loads, even some that are longer than the pick-up bed, to be carried on the tonneau cover while enabling use of the pick-up bed for other cargo.

Abstract: A friction stir processing (FSP) tool includes a pin having a pin body and a rotational axis. The pin is configured to rotate about the rotational axis in a rotational direction. The pin has a radial protrusion protruding radially from the pin body, and the radial protrusion has a working surface oriented in the rotational direction with a depth in a radial direction relative to the rotational axis.

Abstract: A system and method for providing a folding load bearing hard tonneau cover, wherein each folding section is constructed using friction stir welds for strength, stiffness and visual appeal, wherein edge extrusions may include an integral attachment track which is capable of sustaining high tie down loads, wherein a spring loaded latching system has the strength to react the moments generated by heavy loads on top of the tonneau cover, wherein installation does not require modification to the bed but instead uses a 2 bolt attachment system, and wherein the tonneau cover may carry heavy loads on top that are easy to secure, and wherein a custom carrying frame is easily attachable to the tonneau cover to enable large and heavy loads, even some that are longer than the pick-up bed, to be carried on the tonneau cover while enabling use of the pick-up bed for other cargo.

Abstract: A system and method for providing a folding load bearing hard tonneau cover which includes a hinge/connection element using a novel friction stir welding method to weatherproof the bed contents, wherein each folding section is constructed using friction stir welds for strength, stiffness and visual appeal, wherein the system does not rely on attached bed rails to support and lock the cover because loads are reacted on the bed caps, wherein a spring loaded latching system has the strength to react the moments generated by heavy loads on top of the cover, wherein installation does not require modification to the bed, and wherein the tonneau cover may carry heavy loads on top that are easy to secure, while still allowing a cover that folds open.

Abstract: A system and method for securely joining a high melting temperature material and a backing substrate using a mechanical connection includes a backing substrate integrally formed with a material positioned inside a dovetail recess in the high melting temperature material, mechanically fixing the backing substrate to the high melting temperature material without fusion or bonding of the microstructure.

Abstract: A system and method for providing a folding load bearing hard tonneau cover which includes a hinge/connection element using a novel friction stir welding method to weatherproof the bed contents, wherein each folding section is constructed using friction stir welds for strength, stiffness and visual appeal, wherein the system does not rely on attached bed rails to support and lock the cover because loads are reacted on the bed caps, wherein a spring loaded latching system has the strength to react the moments generated by heavy loads on top of the cover, wherein installation does not require modification to the bed, and wherein the tonneau cover may carry heavy loads on top that are easy to secure, while still allowing a cover that folds open.

Abstract: A system and method for modifying a work piece surface of high melting temperature materials such as Advanced High Strength Steels, wherein a friction stir welding tool may include cutting elements located on the outside diameter of a collar assembly, wherein the collar assembly may be retrofitted for existing friction stir welding tools, or may be designed as a custom attachment for a new hybrid friction stir welding tool, wherein the surface of the work piece may be modified by removing detrimental flash and burr created during operation of the friction stir welding tool.

Abstract: A system and method for modifying a work piece surface of high melting temperature materials such as Advanced High Strength Steels, wherein a friction stir welding tool may include cutting elements located on the outside diameter of a collar assembly, wherein the collar assembly may be retrofitted for existing friction stir welding tools, or may be designed as a custom attachment for a new hybrid friction stir welding tool, wherein the surface of the work piece may be modified by removing detrimental flash and burr created during operation of the friction stir welding tool.

Abstract: A system and method for modifying a work piece surface of high melting temperature materials such as Advanced High Strength Steels, wherein a friction stir welding tool may include cutting elements located on the outside diameter of a collar assembly, wherein the collar assembly may be retrofitted for existing friction stir welding tools, or may be designed as a custom attachment for a new hybrid friction stir welding tool, wherein the surface of the work piece may be modified by removing detrimental flash and burr created during operation of the friction stir welding tool.

Abstract: A system and method for using Friction Stir Spot Joining (FSSJ) to join workpieces made of Advanced High Strength Steels (AHSS), wherein a first embodiment is a FSSJ tool that has no surface features, and wherein the rate of rotation of the FSSJ tool is much higher than is used in other FSW techniques to thereby reduce torque by causing plasticization of the AHSS on a small scale, and in a second embodiment, conventional FSSJ tools can be used at conventional FSSJ speeds if the FSSJ tool is manufactured from conductive tool materials having a high hardness, and heating of the FSSJ tool and/or the workpieces enhances the ability of the FSSJ tool to functionally weld the AHSS.

Abstract: A tool is provided that is capable of friction stir processing, friction stir mixing, and friction stir welding of high melting temperature and low melting temperature materials, wherein the collar is now divided into at least an inner and an outer collar coupled to the shank and the FSW tip, wherein new thermal barriers enable expansion of the inner collar to be directed inward to thereby create compression on the FSW tip instead of allowing the FSW tip to become loose in the tool at elevated temperatures.

Abstract: A system and method for using Friction Stir Spot Joining (FSSJ) to join workpieces made of Advanced High Strength Steels (AHSS), wherein a first embodiment is a FSSJ tool that has no surface features, and wherein the rate of rotation of the FSSJ tool is much higher than is used in other FSW techniques to thereby reduce torque by causing plasticization of the AHSS on a small scale, and in a second embodiment, conventional FSSJ tools can be used at conventional FSSJ speeds if the FSSJ tool is manufactured from conductive tool materials having a high hardness, and heating of the FSSJ tool and/or the workpieces enhances the ability of the FSSJ tool to functionally weld the AHSS.

Abstract: A tool is provided that is capable of friction stir processing, friction stir mixing, and friction stir welding of high melting temperature and low melting temperature materials, wherein the collar is now divided into at least an inner and an outer collar coupled to the shank and the FSW tip, wherein new thermal barriers enable expansion of the inner collar to be directed inward to thereby create compression on the FSW tip instead of allowing the FSW tip to become loose in the tool at elevated temperatures.