Abstract: A method of forming an internal channel within a workpiece. In an embodiment, the method includes (a) rotating a tool about a central axis, wherein the tool includes: a shoulder; a pin extending axially from the shoulder; and a flange mounted to the pin that is spaced from the shoulder along the central axis. In addition, the method includes (b) moving the tool across the workpiece in a radial direction with respect to the central axis during (a). Further, the method includes (c) engaging the shoulder of the tool with an outer surface of the workpiece during (a) and (b), (d) submerging the pin and the flange within the workpiece during (a) and (b); and (e) forming the internal channel with the flange during (a) and (b).

Abstract: A friction stir processing tool and method for manufacturing the same are provided. The tool includes a non-consumable, interchangeable friction stir probe body. The tool includes a material flow path defined by an outer surface of a probe body, which has a non-linear, continuous, monotonically-decreasing axial profile. The probe body is adapted to engage a workpiece material to perform a friction stir process by rotating about an axis thereof thereby directing a weld material toward a distal end of the probe body along the flow path. The flow path varies in pitch as the lateral cross-sectional dimension of the probe body decreases toward the distal end thereby causing the weld material to maintain a controlled speed as it travels along the flow path. Geometric surface features such as threads, helical grooves, ridges, flutes, and/or flats, integrated with the probe body may define the flow path.

Abstract: An apparatus includes a connector and is configured to mount to a machine having multiple axes of control. A control signal on the connector determines a path of a rotating tool holder.

Abstract: A mandrel tool probe is provided for performing a friction-stir process. The mandrel tool probe includes a shank and a tip coupled to the shank, where the shank and tip are concentric and rotatable about a given axis. The tip includes a set of a plurality of physically-separate, spiraled surfaces each of which has a linear or curved cross-section that extends along a length of the tip at a constant or varying spiral angle around the circumference of the tip. The tip also has a cross-section with a constant shape along the length of the tip, with the cross-section of the tip including a plurality of major segments each of which is formed of the cross-section of a respective spiraled surface.

Abstract: An apparatus includes a connector and is configured to mount to a machine having multiple axes of control. A control signal on the connector determines a path of a rotating tool holder.

Abstract: A mandrel tool probe is provided for performing a friction-stir process. The mandrel tool probe includes a shank and a tip coupled to the shank, where the shank and tip are concentric and rotatable about a given axis. The tip includes a set of a plurality of physically-separate, spiraled surfaces each of which has a linear or curved cross-section that extends along a length of the tip at a constant or varying spiral angle around the circumference of the tip. The tip also has a cross-section with a constant shape along the length of the tip, with the cross-section of the tip including a plurality of major segments each of which is formed of the cross-section of a respective spiraled surface.

Abstract: A friction stir welding tool having a shoulder section with a scroll pattern that terminates prior to the edge or boundary of the shoulder section to create a scroll-free concentric surface area.

Abstract: A friction stir welding tool having one or more tapered flats for promoting flow of weld material toward the pin terminus and one or more counter-spiraling channels or threads which for promoting flow of the weld material toward the tool shoulder.

Abstract: An apparatus includes a connector and is configured to mount to a machine having multiple axes of control. A control signal on the connector determines a path of a rotating tool holder.

Abstract: A friction stir welding tool having one or more tapered flats for promoting flow of weld material toward the pin terminus and one or more counter-spiraling channels or threads which for promoting flow of the weld material toward the tool shoulder.

Abstract: A friction stir welding tool having a shoulder section with a scroll pattern that terminates prior to the edge or boundary of the shoulder section to create a scroll-free concentric surface area.

Abstract: A system and associated friction stir welding (FSW) assembly, controller and method for performing a friction stir welding operation are provided. The friction stir welding system includes a FSW device, such as a CNC machine, that includes an actuator capable of moving a FSW tool relative to a workpiece. The system also includes a controller capable of controlling the FSW device to drive the actuator to move the FSW tool. In this regard, the actuator is capable of being driven such that the FSW tool is capable of performing a friction stir welding operation on the workpiece. The controller is capable of monitoring a torque of the actuator to thereby control the FSW device to drive the actuator such that the torque is maintained within a range about a torque setting.

Abstract: There is provided a mandrel for spin forming that has a backing plate with removably attached mandrel portions and mandrel spacers, such that the mandrel is adaptable to numerous configurations. The various configurations of the mandrel are used to provide different spin forming contour surfaces upon which metal sheets or other spin formable materials can be spin formed. The adaptable mandrel also provides the ability to create a desired spin formed product from either a single metal sheet or multiple metal sheets joined by friction stir welding or other suitable processes. A spin formed welded metal sheet may also undergo a trimming process to remove the portions of the welded metal sheet having sufficiently different material properties resulting from the weld process, including the weld joint.

Abstract: A system and associated friction stir welding (FSW) assembly, controller and method for performing a friction stir welding operation are provided. The friction stir welding system includes a FSW device, such as a CNC machine, that includes an actuator capable of moving a FSW tool relative to a workpiece. The system also includes a controller capable of controlling the FSW device to drive the actuator to move the FSW tool. In this regard, the actuator is capable of being driven such that the FSW tool is capable of performing a friction stir welding operation on the workpiece. The controller is capable of monitoring a torque of the actuator to thereby control the FSW device to drive the actuator such that the torque is maintained within a range about a torque setting.

Abstract: There is provided a mandrel for spin forming that has a backing plate with removably attached mandrel portions and mandrel spacers, such that the mandrel is adaptable to numerous configurations. The various configurations of the mandrel are used to provide different spin forming contour surfaces upon which metal sheets or other spin formable materials can be spin formed. The adaptable mandrel also provides the ability to create a desired spin formed product from either a single metal sheet or multiple metal sheets joined by friction stir welding or other suitable processes. A spin formed welded metal sheet may also undergo a trimming process to remove the portions of the welded metal sheet having sufficiently different material properties resulting from the weld process, including the weld joint.