Abstract: A method of forming an internally-arranged laser-beam weld from within a composite structure. The method includes arranging a welding apparatus within an internal passage of the composite structure, and emitting a laser beam from the welding apparatus to form the internally-arranged laser-beam weld between layers of the composite structure.

Abstract: A corrosion-resistant cover system, having a corrosion-resistant cover structured and configured to be arrangeable around an object having one or more metallic surfaces that are susceptible to corrosion. The corrosion-resistant cover is operable to provide increased corrosion resistance to the object by preventing contact between the one or more metallic surfaces and ambient conditions exterior to the corrosion-resistant cover.

Abstract: A corrosion-resistant cover system, having a corrosion-resistant cover structured and configured to be arrangeable around an object having one or more metallic surfaces that are susceptible to corrosion. The corrosion-resistant cover is operable to provide increased corrosion resistance to the object by preventing contact between the one or more metallic surfaces and ambient conditions exterior to the corrosion-resistant cover.

Abstract: A method of forming an internally-arranged laser-beam weld from within a composite structure. The method includes arranging a welding apparatus within an internal passage of the composite structure, and emitting a laser beam from the welding apparatus to form the internally-arranged laser-beam weld between layers of the composite structure.

Abstract: A method comprises fusion welding a filler metal to a first aluminum component; wherein the first aluminum component comprises a 7xxx series aluminum alloy; and wherein the filler metal comprises an aluminum alloy, in weight percent: up to 0.15 Fe; up to 0.15 Si; from 2.3 to 2.7 Mg; from 1.4 to 1.8 Cu; from 6.0 to 9.0 Zn; and from 0.06 to 0.14 Zr. In some embodiments, the 7xxx series aluminum alloy comprises 0.5-2.6 wt. % Cu. In some embodiments, the filler metal comprises, in weight percent, up to 0.45 Sc.

Abstract: Al—Mg and Al—Mg—Zn weld filler alloy compositions for use with fusion weldable 7xxx, 6xxx, 5xxx and 2xxx series aluminum alloy base metals are disclosed. The weld filler alloys may be used for joining a first aluminum base metal segment to a second aluminum base metal segment, where the base metal segments is at least one of 7xxx, 6xxx, 5xxx and 2xxx series aluminum alloy. The weld filler alloys, in wire or rod form, may also be used to repair a defective weld.

Abstract: One embodiment of the present invention relates to a system for buried-arc welding with thru-the-arc seam tracking. Another embodiment of the present invention relates to a method for buried-arc welding with thru-the-arc seam tracking.

Abstract: A welded electrical connection includes an aluminum electrical conductor welded to a copper electrical conductor. The copper electrical conductor and the aluminum electrical conductor form a butt joint, A ferrule is over the butt joint and attached to the copper electrical conductor and the aluminum electrical conductor. The ferrule is not directly attached to welded portions of the copper electrical conductor and the aluminum electrical conductor. In some embodiments, weld flash is between the butt joint and the ferrule.

Abstract: A multi-shouldered friction stir welding tool comprises an exterior threaded solid pin having a diameter and a length; a shoulder having a threadless inner diameter slightly larger than the diameter of the exterior threaded solid pin and at least one substantially radial threaded set screw hole; an monolithic shoulder-shank having a threadless inner diameter slightly larger than the diameter of the exterior threaded solid pin and at least one substantially radial threaded set screw hole; a pair of locking nuts having a threadless outer diameter and a threaded inner diameter operably compatable with the exterior threaded solid pin, wherein the shoulder and the monolithic shoulder-shank are capable of slidable engagement with the exterior threaded solid pin along the length of the exterior threaded solid pin to set a space slightly larger than a thickness of a work piece to be welded.

Abstract: A multi-shouldered friction stir welding tool comprises an exterior threaded solid pin having a diameter and a length; a shoulder having a threadless inner diameter slightly larger than the diameter of the exterior threaded solid pin and at least one substantially radial threaded set screw hole; an monolithic shoulder-shank having a threadless inner diameter slightly larger than the diameter of the exterior threaded solid pin and at least one substantially radial threaded set screw hole; a pair of locking nuts having a threadless outer diameter and a threaded inner diameter operably compatable with the exterior threaded solid pin, wherein the shoulder and the monolithic shoulder-shank are capable of slidable engagement with the exterior threaded solid pin along the length of the exterior threaded solid pin to set a space slightly larger than a thickness of a work piece to be welded.

Abstract: One embodiment of a friction stir welding apparatus comprises two friction stir welding tools on a carriage. The first friction stir welding tool is capable of rotating in a first direction. The second friction stir welding tool is capable of rotating in a second direction, counter to the first direction. The first friction stir welding tool and the second friction stir welding tool are operable to weld simultaneously and in tandem along an intersection of at least two work pieces.

Abstract: Methods for welding a first metal part to a second metal part by a solid state process to form a welded article having at least a welded region are provided herein. The welded region of the weld is post-weld aged by heating it to a set temperature for a set time and compressing the weld.

Abstract: A multi-shouldered friction stir welding tool (10) comprises an integral shank-pin unit (11) having a plurality of pin portions on the shank-pin unit, where the plurality of pin portions for driving into a plurality of joints to perform a friction stir welding operation on the corresponding plurality of joints and, where a shank portion of the shank-pin unit is for attachment to an optional axial tension rod (19), each of the friction stir welding modules comprises a pair of shoulders (13, 14) that is connected to the shank-pin unit where each shoulder has a distal end and a proximal end, where the proximal end of each shoulder faces the pin portion of the shank-pin unit, whereby the shoulder and pin(s) rotate in unison, and a pair of split collars or a pair of nuts that is connected to the shank-pin unit and faces the distal end of each shoulder, where the plurality of friction stir welding modules are connected to each other whereby the modules rotate in unison to simultaneously make a plurality of parallel

Abstract: Structural connectors for watercrafts, buildings and aircrafts are disclosed. In general, each structural connector includes at least a pair of members extending outwardly from and substantially perpendicular to a body of the structural connector, the members spaced apart from one another so as to form a recess therein between. In some embodiments, the recess may be sized and shaped for receiving supporting members including the likes of stringers and support plates.

Abstract: An assembly includes a first structural member made from a first material, such as aluminum, and having a first and a second flange, a second structural member having a first and a second flange and made from a second material, such as magnesium, and a third and a fourth structural member made from the first material and each having a first and second flange for contacting with the flanges of the first and second structural members so as to lock the first and second members together.

Abstract: A multi-shouldered friction stir welding tool comprises an integral shank-pin unit having a plurality of pin portions for driving into a plurality of joints. A shank portion of the shank-pin unit is for attachment to an optional axial tension rod. A plurality of friction stir welding modules comprise a pair of shoulders that is connected to the shank-pin unit. The proximal end of each shoulder faces the pin portion of the shank-pin unit, whereby the shoulder and pin(s) rotate in unison. A pair of split collars or a pair of nuts is connected to the shank-pin unit and faces the distal end of each shoulder. The plurality of friction stir welding modules are connected to each other and rotate in unison to simultaneously make a plurality of parallel welds.

Abstract: The present disclosure relates to fire-resistant systems, methods, and apparatus. In one embodiment, a fire-resistant system includes a fire-resistant panel and a protected material coupled to the fire-resistant panel. The fire-resistant panel includes a passive layer and a back layer. The passive layer comprises a phyllosilicate material. The back layer comprises an inorganic material and may be coupled to the passive layer. Optionally, the fire-resistant panel may include a secondary layer comprising a functional material, where the functional material comprises one of a phase change material or an endothermic material.

Abstract: 7xxx aluminum alloy weld filler alloys and methods of using the same are described. The 7xxx aluminum alloy weld filler alloys may be used to repair 7xxx alloy products. The repaired volume of the 7xxx alloy products may be substantially crack-free, and may facilitate reuse of the repaired 7xxx alloy products.

Abstract: Portable friction stir welding apparatus having a crawler which supports a motor for rotating a Friction Stir Welding tool and is coupled to a drive mechanism for urging the crawler along a predefined weld path on work pieces. The crawler can comprise one member or a set of two or three physically separated members each rotatably coupled to the friction stir welding tool. The friction stir welding tool for making the weld is rotatably coupled to each member and restricts axial displacement of the physically separate members relative to each other. The members are adapted to engage rails on the work pieces which provide at least one of guiding, alignment, fixturing, torque compensation for the members as the friction stir welding tool is rotated and the crawler is moved along a joint.

Abstract: A multi-shouldered friction stir welding tool (10) comprises an integral shank-pin unit (11) having a plurality of pin portions on the shank-pin unit, where the plurality of pin portions for driving into a plurality of joints to perform a friction stir welding operation on the corresponding plurality of joints and, where a shank portion of the shank-pin unit is for attachment to an optional axial tension rod (19), each of the friction stir welding modules comprises a pair of shoulders (13, 14) that is connected to the shank-pin unit where each shoulder has a distal end and a proximal end, where the proximal end of each shoulder faces the pin portion of the shank-pin unit, whereby the shoulder and pin(s) rotate in unison, and a pair of split collars or a pair of nuts that is connected to the shank-pin unit and faces the distal end of each shoulder, where the plurality of friction stir welding modules are connected to each other whereby the modules rotate in unison to simultaneously make a plurality of parallel