Abstract: A method of bonding two or more metallic components into a single piece. The bonding surfaces of the metallic components are protected from reaction with the environment. A force is applied to the metallic components to push the bonding surfaces together. Simultaneous with applying the force, an electric current is passed through the bonding surfaces to joule heat and weld the bonding surfaces together to form the single piece. The bonding surfaces may be protected by plating with a noble metal, applying a coating, shielding with a noble gas, or placing into a vacuum. A press may be used to apply the force. The force and the electric current may be sufficient to push out metal around the joint of the bonding surfaces, and at least one of the bonding surfaces may be drafted to facilitate pushing out the metal. The electric current may be pulsed to induce electroplasticity.

Abstract: A structure and a method of creating the structure in which relatively thin pieces of non-weldable aluminum alloy or other non-weldable material are welded together. First layers of a weldable material, such as a weldable aluminum alloy or other weldable material, having a total thickness of between 0.01 and 0.30 inches, are built up on a surface of the first piece using an ultrasonic or other solid state joining technique, and second layers of the weldable material having a similar total thickness are built up on a surface of the second piece using the same technique. The first piece is then welded to the second piece at the first and second layers of weldable material using a fusion welding technique. The resulting structure may be part of an aircraft, landcraft, watercraft, or spacecraft type of vehicle or may be used in other high-performance applications.

Abstract: A friction stir welding machine and method that injects filler materials into a weld joint and determines the amount of materials to add by monitoring and compensating for insufficient internal weld pressures in the joint. Two workpieces are placed adjacent one another in an abutting relationship with a joint formed between them. A pin tool is inserted in the joint, rotated, and moved along the joint as the pin is rotating so as to mix and heat materials in the joint. Internal weld pressures in the joint adjacent the pin tool are monitored, and filler materials are injection into the joint when an internal weld pressure below a threshold weld pressure is detected.

Abstract: A method and system for joining relatively thick (i.e., at least 0.07 inch, or between 0.08 and 0.24 inch) sheets of non-weldable aluminum or other material using multiple passes of ultrasonic joining and multiple plugs to create a single larger sheet. Angles and profiles are machined onto edges of the sheets, the angles are overlapped to form a scarf joint, and ultrasonic joining is performed on both sides of the scarf joint, resulting in channels where the angles and profiles intersect. Plugs are extruded or otherwise created and positioned in the channels, and ultrasonic joining is used to join the plugs in the channels. Additional plugs are added until the last plugs are proud of the surface, and then the plugs are machined until the joint is flush with the surface. The plugs may be of the same or a different material as the sheets.

Abstract: A method and system for joining relatively thick (i.e., at least 0.07 inch, or between 0.08 and 0.24 inch) sheets of non-weldable aluminum or other material using multiple passes of ultrasonic joining and multiple plugs to create a single larger sheet. Angles and profiles are machined onto edges of the sheets, the angles are overlapped to form a scarf joint, and ultrasonic joining is performed on both sides of the scarf joint, resulting in channels where the angles and profiles intersect. Plugs are extruded or otherwise created and positioned in the channels, and ultrasonic joining is used to join the plugs in the channels. Additional plugs are added until the last plugs are proud of the surface, and then the plugs are machined until the joint is flush with the surface. The plugs may be of the same or a different material as the sheets.

Abstract: A method and system for joining relatively thick (i.e., at least 0.07 inch, or between 0.08 and 0.24 inch) sheets of non-weldable aluminum or other material using multiple passes of ultrasonic joining and multiple plugs to create a single larger sheet. Angles and profiles are machined onto edges of the sheets, the angles are overlapped to form a scarf joint, and ultrasonic joining is performed on both sides of the scarf joint, resulting in channels where the angles and profiles intersect. Plugs are extruded or otherwise created and positioned in the channels, and ultrasonic joining is used to join the plugs in the channels. Additional plugs are added until the last plugs are proud of the surface, and then the plugs are machined until the joint is flush with the surface. The plugs may be of the same or a different material as the sheets.

Abstract: A structure and a method of creating the structure in which relatively thin pieces of non-weldable aluminum alloy or other non-weldable material are welded together. First layers of a weldable material, such as a weldable aluminum alloy or other weldable material, having a total thickness of between 0.01 and 0.30 inches, are built up on a surface of the first piece using an ultrasonic or other solid state joining technique, and second layers of the weldable material having a similar total thickness are built up on a surface of the second piece using the same technique. The first piece is then welded to the second piece at the first and second layers of weldable material using a fusion welding technique. The resulting structure may be part of an aircraft, landcraft, watercraft, or spacecraft type of vehicle or may be used in other high-performance applications.