Abstract: Devices and methods are provided for testing weld strengths of a test coupon joint. A test coupon is positionally fixed to a base of the testing device. A punch assembly having a head portion is provided so as to exert an axial force against an upright part of the test coupon to thereby determine weld strength between the planar and upright parts of the test coupon (e.g., a maximum force at which weld failure occurs).

Abstract: Aircraft fuselage structures have reinforcement members in the vicinity of the stringer openings formed in frame members and are rigidly lap joined to a surface region of the frame members by a friction stir weld region. Such aircraft fuselage structural components may thus be provided with plural longitudinally spaced-apart frame members defining a transversal cross-section of an aircraft fuselage section, the frame members having a plurality of stringer holes therethrough, and plural longitudinally oriented stringers each being positioned within a respective one of the stringer holes of the frame member. The reinforcement members are lap joined to corresponding surfaces of frame members in the vicinity of the stringer holes such that the reinforcement members are joined rigidly to the corresponding surfaces of the frame members by a friction stir weld region.

Abstract: Devices and methods are provided for testing weld strengths of a test coupon joint. A test coupon is positionally fixed to a base of the testing device. A punch assembly having a head portion is provided so as to exert an axial force against an upright part of the test coupon to thereby determine weld strength between the planar and upright parts of the test coupon (e.g., a maximum force at which weld failure occurs).

Abstract: Friction stir welding equipment control force spindle for mounting in an orbital head housing uses a coaxial sensor to measure downforce. Simultaneously, an axial electrical actuator is controlled to dynamically correct the axial tool position during the welding, by a direct axial force system control, in order to maintain controlled downforce according to parameters previously set, based on numerical control. The equipment also sets up, monitors and controls spindle rotation speed, welding speed, acceleration speed and downforce using for example closed loop control functions. A laser system may scan the backing surface before welding and correct original tool path, in order to get an offset tool path. A precision alarm system may provide safe welding while preventing the tool from colliding with the backing surface.

Abstract: Friction stir welding equipment control force spindle for mounting in an orbital head housing uses a coaxial sensor to measure downforce. Simultaneously, an axial electrical actuator is controlled to dynamically correct the axial tool position during the welding, by a direct axial force system control, in order to maintain controlled downforce according to parameters previously set, based on numerical control. The equipment also sets up, monitors and controls spindle rotation speed, welding speed, acceleration speed and downforce using for example closed loop control functions. A laser system may scan the backing surface before welding and correct original tool path, in order to get an offset tool path. A precision alarm system may provide safe welding while preventing the tool from colliding with the backing surface.

Abstract: Friction stir welding (FSW) processes, systems and the resulting friction stir welded components are disclosed whereby first and second workpieces are welded to one another using a first workpiece having mutually orthogonal structural components and a junction region therebetween which defines a bearing surface of predetermined geometry. A shoulder of a FSW tool may be brought into bearing contact with the bearing surface so that a pin extending from the shoulder of the FSW tool may be advanced into and through the one structural component of the first workpiece at an angle relative thereto so as to thereby form a friction stir weld region between the first and second workpieces. Some preferred embodiments will provide a bearing surface which defines an arcuately concave geometry, in which case the shoulder of the FSW tool defines an arcuately convex geometry conformably mateable with the bearing surface.

Abstract: Friction stir welding (FSW) processes, systems and the resulting friction stir welded components are disclosed whereby first and second workpieces are welded to one another using a first workpiece having mutually orthogonal structural components and a junction region therebetween which defines a bearing surface of predetermined geometry. A shoulder of a FSW tool may be brought into bearing contact with the bearing surface so that a pin extending from the shoulder of the FSW tool may be advanced into and through the one structural component of the first workpiece at an angle relative thereto so as to thereby form a friction stir weld region between the first and second workpieces. Some preferred embodiments will provide a bearing surface which defines an arcuately concave geometry, in which case the shoulder of the FSW tool defines an arcuately convex geometry conformably mateable with the bearing surface.

Abstract: Aircraft fuselage structures have reinforcement members in the vicinity of the stringer openings formed in frame members and are rigidly lap joined to a surface region of the frame members by a friction stir weld region. Such aircraft fuselage structural components may thus be provided with plural longitudinally spaced-apart frame members defining a transversal cross-section of an aircraft fuselage section, the frame members having a plurality of stringer holes therethrough, and plural longitudinally oriented stringers each being positioned within a respective one of the stringer holes of the frame member. The reinforcement members are lap joined to corresponding surfaces of frame members in the vicinity of the stringer holes such that the reinforcement members are joined rigidly to the corresponding surfaces of the frame members by a friction stir weld region.