Abstract: An apparatus comprises a machine module and an instrument module. The machine module is capable of being connected to a power tool. The instrument module is capable of being connected to the machine module and capable of generating a number of signals containing information about a number of operating conditions during operation of the power tool.

Abstract: Apparatus for performing operations on a workpiece includes a clamping assembly mounted on a tool support for movement along at least one axis independent of the axes along which the tool moves. The clamping assembly includes clamping devices for applying clamping pressure to the workpiece, and a rotary drive mounted on the tool support for rotating the clamping devices around the independent axis. The clamping devices include clamping packs having a clamping roller mounted on a pneumatically driven slide for applying a programmed amount of clamping pressure to the workpiece.

Abstract: An apparatus and method for separating a pin tool from a shoulder tool, after the pin tool and shoulder tool have become welded together during a friction stir welding operation. In one exemplary embodiment a frame is used to support the shoulder tool. A fluid pressure actuating assembly is used for gradually exerting a force on the pin tool while the shoulder tool is held stationary within the frame. The gradually increasing force gradually breaks the weld and separates the pin tool from the shoulder tool without damaging the pin tool.

Abstract: A method and system for identifying and reducing costs of information technology actions in real time. Initiation of an information technology (IT) action by a user is detected. An actual cost to perform the IT action is determined in real time prior to a completion of the IT action. A target cost (e.g., average cost) to perform the IT action is obtained. The actual cost is determined to be greater than the target cost. Recommended actions for reducing the actual cost are obtained. A notification is presented to the user in real time and prior to the completion of the IT action. The notification includes a description or a link to a description of the recommended actions.

Abstract: A method of manufacturing a workpiece is provided. The method generally includes friction stir welding at least one structural member, selectively removing material from the surfaces of the workpiece at the location of a friction stir weld joint, and thereafter subjecting the workpiece to a solution treat, quench, and age treatment. By selectively removing regions from the surfaces of the workpiece that are defined by nonuniform material properties adapted to nucleate nonuniform grain growth during the solution treat, quench, and age treatment, a subsequent grain growth during the thermal treatment can be at least partially prevented.

Abstract: An apparatus and methods for clamping around a manufacturing tool engaging a work piece are described. In one embodiment, a clamp includes a moveable support arranged to at least partially surround a circumference defining a work area. A friction reducing element is attached to the support to apply pressure to the surface when the clamp is engaged with the work piece, and to allow the clamp to be moved with the manufacturing tool. In accordance with other aspects of the invention, the clamp co-annularly or partially surrounds the manufacturing tool. In another embodiment, the manufacturing tool is a friction stir welding tool.

Abstract: Systems and methods for verifying a materials processing path on a work piece are described. In one embodiment, a system for verifying a material process path on a work piece includes a processing unit operable to receive processing instructions to control a motion of a machine tool device relative to a work piece. A tool holder of the machine tool device retains a tool path tracing assembly that applies a mark to a surface of the work piece as the assembly is moved along the material process path.

Abstract: Apparatus for performing operations on a workpiece includes a clamping assembly mounted on a tool support for movement along at least one axis independent of the axes along which the tool moves. The clamping assembly includes clamping devices for applying clamping pressure to the workpiece, and a rotary drive mounted on the tool support for rotating the clamping devices around the independent axis. The clamping devices include clamping packs having a clamping roller mounted on a pneumatically driven slide for applying a programmed amount of clamping pressure to the workpiece.

Abstract: A process control system for a friction stir welding machine employs a master set of parameters and subroutines to control multiple machine processes, including welding, drilling, milling and probing. Sub-sets of the master set comprising command parameters, limits parameters and measurement parameters are used to control the operation of a weld tip, a clamping system and a motion head that cooperate under computer control to carry out the multiple processes.

Abstract: A clamping system can be reconfigured to clamp any of multiple workpieces having differing shapes. The system includes a retention assembly for retaining an inflatable bladder that applies a clamping force to the workpiece. The retention assembly includes a flexible chain of pivotally connected links that can be locked in place to form a rigid assembly that conforms to the shape of the workpiece. The links can be unlocked to allow reconfiguration of the retention assembly into shapes matching other workpieces.

Abstract: A method for operating a diesel internal combustion engine having a compressed air source, a diesel particulate filter situated in the exhaust gas system, and a secondary air line and secondary air compressor for introducing secondary air into the exhaust gas system of the internal combustion engine, in which the compressed air source is used to drive the secondary air compressor.

Abstract: A spindle head for performing friction stir welding includes concentric spindle shafts driven by stacked, coaxial motors contained within a spindle housing. The coaxial arrangement of the motors results in a more compact package. Each of the motors is concentrically arranged around one of the spindles by directly connecting a rotor of the motor to a spindle shaft. The stators of the motors are mounted on the housing and are concentrically arranged around the concentric spindle shafts.

Abstract: Systems and methods for verifying a materials processing path on a work piece are described. In one embodiment, a system for verifying a material process path on a work piece includes a processing unit operable to receive processing instructions to control a motion of a machine tool device relative to a work piece. A tool holder of the machine tool device retains a tool path tracing assembly that applies a mark to a surface of the work piece as the assembly is moved along the material process path.

Abstract: The present invention is directed to systems and methods for clamping along a workpiece. In one embodiment, a clamping system includes an elongated member adapted to be positioned across a workpiece, and an elongated bladder adapted to be positioned between the member and the workpiece. The bladder applies a clamping force to the workpiece when the bladder is inflated. In another aspect of the invention, the system includes a plurality of clamp supports, supporting clamp bars. A high temperature hose is positioned between the clamp bar and the workpiece. The hose applies a clamping force to the workpiece when the hose is inflated. In accordance with other aspects of the invention, a method of clamping includes bridging the skin and substructure with an elongated clamp support, and inflating an elongated bladder between the clamp support and the skin, thereby clamping the skin to the substructure.

Abstract: A method of stir welding T-joints comprises assembling and stir welding first and second members. The first member comprises a sheet portion of material and also comprises restraining surfaces. The second member comprises a rib. The rib is stir welded to the sheet portion with the edge margin of the rib being positioned between the restraining surfaces of the first member. During stir welding, the restraining surfaces of the first member limit movement of the rib relative to the first member. A tooling portion is preferably formed as a contiguous portion of the material of one of the first and second members. The first and second members are secured to a stir welding apparatus via the tooling portion during the stir welding. The method yet further comprises a step of separating the tooling portion from the first and second members after forming the stir welded T-joint.

Abstract: A sealant for a weld joint and an associated weld joint and method are provided. The sealant includes aluminum and germanium and is characterized by a melting temperature that is lower than the melting temperature of the structural member that is joined. The sealant, which is disposed between faying surfaces of the structural members, can fill the spaces between the structural members to prevent the entry of chemicals, moisture, debris, and other substances, thereby reducing the likelihood of corrosion of the joint or structural members at the interface. Further, the sealant can be diffusion bonded to the faying surfaces, for example, by the heat generated during the joining process.

Abstract: The present invention is directed to apparatus and methods for clamping along a work piece. In one embodiment, a clamping system includes one or more force applying units each including a plunger or force applying member adapted to apply clamping force to the work piece, and one or more coupling units linked with the force applying units forming a chain of force applying units and coupling units. The coupling units may include a lockable pivot adapted to pivot to conform the chain to the surface of the work piece when unlocked, and adapted to be locked when at least one of the plurality of force applying units applies clamping force to the work piece. In another embodiment, a clamping system may include multi-axis pivot units. In a further embodiment, a clamping system may include length adjusting units.

Abstract: The present invention is directed to apparatus and methods for clamping around a manufacturing tool engaging a work piece. In one embodiment, a clamp includes a moveable support arranged to at least partially surround a circumference defining a work area. A friction reducing element is attached to the support to apply pressure to the surface when the clamp is engaged with the work piece, and to allow the clamp to be moved with the manufacturing tool. In accordance with other aspects of the invention, the clamp co-annularly or partially surrounds the manufacturing tool. In another embodiment, the manufacturing tool is a friction stir welding tool.

Abstract: A sealant for a weld joint and an associated weld joint and method are provided. The sealant includes aluminum and germanium and is characterized by a melting temperature that is lower than the melting temperature of the structural member that is joined. The sealant, which is disposed between faying surfaces of the structural members, can fill the spaces between the structural members to prevent the entry of chemicals, moisture, debris, and other substances, thereby reducing the likelihood of corrosion of the joint or structural members at the interface. Further, the sealant can be diffusion bonded to the faying surfaces, for example, by the heat generated during the joining process.

Abstract: A lubricator apparatus comprises a tank having a lower portion forming a reservoir for lubricating oil to be combined with compressed air to form a lubricating air-oil mist. The tank bottom has a surface exposed to the lubricating oil in the tank and an air passageway therethrough between an air inlet and an air outlet through which the compressed air is passed before it enters the tank. A solenoid valve is mounted in a heat-transfer relationship to the tank bottom, the valve operatively controlling the air passageway, whereby heat generated by solenoid operation is transferred to the lubricating oil to raise the temperature of the oil. The tank bottom may also include a filter and condensate drain system to filter the compressed air and remove moisture therefrom.