Abstract: A curved extrusion includes a body that has indefinite length and a cross-section, and that is formed to contour and at least one channel cut into the cross-section that is filled with deposited material such that said cross-section of said body is restored. By cutting the channels into the cross-section of the extrusion, the extrusion may be easily formed onto a contoured tool to be curved with lower forming and residual stresses and distortion. By filling the channels with deposited material, the original cross-section and strength of the extrusion can be restored. By adding a transverse stiffener, the strength of the original extrusion may not only be restored but also further improved. By depositing material to create structural features the cross-section of the extrusion may be locally changed. The method for forming curved extrusions of the present invention may be used, for example, to produce T-chords of an aircraft.

Abstract: A preform and method for forming a structural assembly are provided. The preform can be formed by friction welding structural members to a base member and subsequently providing a connection material to join the structural members. The resulting preform can be formed with dimensions and a configuration that approximate the dimensions and configuration of the structural assembly. Thus, the structural assembly can be formed by joining multiple members that are generally smaller than the finished assembly.

Abstract: A method for forming an aluminum alloy article having improved mechanical properties using a solid-state joining process in which the problem of ductility reduction is minimized by conducting a thermal exposure treatment prior to solution heat treatment. This thermal exposure treatment, done at a temperature below the solution heat treatment temperature, releases stored energy in the aluminum-alloy material. The aluminum-alloy material then does not have sufficient energy to cause recrystallization and abnormal grain growth during the subsequent solution heat treatment process. The resultant aluminum-alloy material has a restored mechanical strength with only a minor, but acceptable, decrease in original ductility.

Abstract: A preform and method for forming a structural assembly are provided. The preform can be formed by friction welding structural members to a base member and subsequently providing a connection material to join the structural members. The resulting preform can be formed with dimensions and a configuration that approximate the dimensions and configuration of the structural assembly. Thus, the structural assembly can be formed by joining multiple members that are generally smaller than the finished assembly.

Abstract: A preform and method for forming a structural assembly are provided. The preform can be formed by friction welding structural members to a base member and subsequently providing a connection material to join the structural members. The resulting preform can be formed with dimensions and a configuration that approximate the dimensions and configuration of the structural assembly. Thus, the structural assembly can be formed by joining multiple members that are generally smaller than the finished assembly.

Abstract: An apparatus and method for joining structural members to form preforms and structural assemblies are provided. The structural members are positioned so that joining surfaces thereof define an angled aperture, such a slot or frustoconical bore, that receives a corresponding joining member. The joining member is urged into the aperture against the joining surfaces and moved, for example, by oscillating or rotating the joining member, to friction weld the joining member to the structural members. Each structural member can include a clamping portion that is received by a clamping device that prevents the aperture from opening as the joining member is urged into the aperture. A gripping portion of the joining member and the clamping portions of the structural members can be trimmed from the resulting preform to form a finished structural assembly.

Abstract: A curved extrusion includes a body that has indefinite length and a cross-section, and that is formed to contour and at least one channel cut into the cross-section that is filled with deposited material such that said cross-section of said body is restored. By cutting the channels into the cross-section of the extrusion, the extrusion may be easily formed onto a contoured tool to be curved with lower forming and residual stresses and distortion. By filling the channels with deposited material, the original cross-section and strength of the extrusion can be restored. By adding a transverse stiffener, the strength of the original extrusion may not only be restored but also further improved. By depositing material to create structural features the cross-section of the extrusion may be locally changed. The method for forming curved extrusions of the present invention may be used, for example, to produce T-chords of an aircraft.

Abstract: A preform and method for forming a structural assembly are provided. The preform can be formed by friction welding structural members to a base member and subsequently providing a connection material to join the structural members. The resulting preform can be formed with dimensions and a configuration that approximate the dimensions and configuration of the structural assembly. Thus, the structural assembly can be formed by joining multiple members that are generally smaller than the finished assembly.

Abstract: A preform and method for forming preforms and structural members are provided. The preform can be formed by cold spraying a structural material onto a base member, such that the preform has dimensions approximating the dimensions of the machined structural member to thereby reduce material waste and machining time when forming the structural member from the preform. In addition, the preforms can be plastically deformed to more closely correspond with the desired dimensions of the structural member. Further, hydrogen can be provided in a mixed stream of gas and structural material for spraying, and the resulting structural member can be subjected to a sub-atmospheric pressure to release hydrogen therefrom.

Abstract: A method of making tailored blanks in accordance with one embodiment comprises the steps of friction welding a first joining surface of a first structural member having a substantially non-rectangular parallelogram profile to a first portion of a joining surface of a substrate; and thereafter concurrently linear friction welding first and second joining surfaces of a second structural member having a substantially non-rectangular parallelogram profile to a second portion of the surface of the substrate and to a second joining surface of the first structural member respectively. The first and second portions of the surface of the substrate are adjacent. Two or more structural members having a substantially non-rectangular parallelogram profile can be linear friction welded in succession to the substrate and to each other, thereby building a structural assembly having a long flange or other long feature of a desired length.

Abstract: An assembly for positioning a structural assembly for friction stir welding, and a system and method for friction stir welding the structural assembly are provided. The assembly includes an engaging structure and at least one tooling block capable of engaging the engaging structure, as well as a substructure positioned adjacent to the engaging structure and tooling block. The substructure and engaging structure capable of being friction stir welded together to form a butt joint therebetween.

Abstract: A structural assembly and a preform and method for forming the structural assembly are provided. The preform can be formed by linear friction welding structural members to a base member and friction welding each structural member to at least one of the other structural members. The resulting preform can be formed with dimensions and a configuration that approximate the dimensions and configuration of the structural assembly. Thus, the structural assembly can be formed by joining multiple members that are generally smaller than the finished assembly.

Abstract: An assembly for positioning a structural assembly for friction stir welding, and a system and method for friction stir welding the structural assembly are provided. The assembly includes a frame defining an aperture therein, and at least one structural member positioned within the aperture. The assembly also includes at least one spacer positioned within the aperture such that the spacer and structural member substantially fill the aperture to secure the structural member within the frame, as well as a substrate secured to the frame and positioned adjacent to the structural member in an overlapping configuration to define an interface between the substrate and structural member. In this configuration, the substrate and structural member are capable of being friction stir welded together.

Abstract: A preform and method for forming preforms and structural members are provided. The preform can be formed by cold spraying a structural material onto a base member, such that the preform has dimensions approximating the dimensions of the machined structural member to thereby reduce material waste and machining time when forming the structural member from the preform. In addition, the preforms can be plastically deformed to more closely correspond with the desired dimensions of the structural member. Further, hydrogen can be provided in a mixed stream of gas and structural material for spraying, and the resulting structural member can be subjected to a sub-atmospheric pressure to release hydrogen therefrom.

Abstract: An apparatus and method for joining structural members to form preforms and structural assemblies are provided. The structural members are positioned so that joining surfaces thereof define an angled aperture, such a slot or frustoconical bore, that receives a corresponding joining member. The joining member is urged into the aperture against the joining surfaces and moved, for example, by oscillating or rotating the joining member, to friction weld the joining member to the structural members. Each structural member can include a clamping portion that is received by a clamping device that prevents the aperture from opening as the joining member is urged into the aperture. A gripping portion of the joining member and the clamping portions of the structural members can be trimmed from the resulting preform to form a finished structural assembly.

Abstract: A method of constructing a preform for use in forming a machined structural assembly is provided. The method includes determining the dimensions of the machined structural assembly. First and second structural members are selected based on the predetermined dimensions of the machined structural assembly. The first structural member is positioned adjacent the second structural member so as to define at least two contact surfaces. The contact surfaces of the first and second structural members are friction welded to construct the preform such that the preform has dimensions approximating the dimensions of the machined structural assembly to thereby reduce material waste when forming the machined structural assembly. A machined structural assembly having predetermined dimensions is formed from the preform by machining away excess material.

Abstract: An apparatus and method for joining structural members to form preforms and structural assemblies are provided. The structural members are positioned so that joining surfaces thereof define an angled aperture, such a slot or frustoconical bore, that receives a corresponding joining member. The joining member is urged into the aperture against the joining surfaces and moved, for example, by oscillating or rotating the joining member, to friction weld the joining member to the structural members. Each structural member can include a clamping portion that is received by a clamping device that prevents the aperture from opening as the joining member is urged into the aperture. A gripping portion of the joining member and the clamping portions of the structural members can be trimmed from the resulting preform to form a finished structural assembly.

Abstract: An apparatus and method for joining structural members to form preforms and structural assemblies are provided. The structural members are positioned so that joining surfaces thereof define an angled aperture, such a slot or frustoconical bore, that receives a corresponding joining member. The joining member is urged into the aperture against the joining surfaces and moved, for example, by oscillating or rotating the joining member, to friction weld the joining member to the structural members. Each structural member can include a clamping portion that is received by a clamping device that prevents the aperture from opening as the joining member is urged into the aperture. A gripping portion of the joining member and the clamping portions of the structural members can be trimmed from the resulting preform to form a finished structural assembly.

Abstract: An apparatus and method for joining structural members to form preforms and structural assemblies are provided. The structural members are positioned so that joining surfaces thereof define an angled aperture, such a slot or frustoconical bore, that receives a corresponding joining member. The joining member is urged into the aperture against the joining surfaces and moved, for example, by oscillating or rotating the joining member, to friction weld the joining member to the structural members. Each structural member can include a clamping portion that is received by a clamping device that prevents the aperture from opening as the joining member is urged into the aperture. A gripping portion of the joining member and the clamping portions of the structural members can be trimmed from the resulting preform to form a finished structural assembly.

Abstract: A method of constructing a preform for use in forming a machined structural assembly is provided. The method includes determining the dimensions of the machined structural assembly. First and second structural members are selected based on the predetermined dimensions of the machined structural assembly. The first structural member is positioned adjacent the second structural member so as to define at least two contact surfaces. The contact surfaces of the first and second structural members are friction welded to construct the preform such that the preform has dimensions approximating the dimensions of the machined structural assembly to thereby reduce material waste when forming the machined structural assembly. A machined structural assembly having predetermined dimensions is formed from the preform by machining away excess material.