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: 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: Embodiments of tool mounted structural positioning devices and techniques are described. In one embodiment, a positioning device includes mountings to mount the device directly to a tool device configured to travel a path and perform a manufacturing operation on an element. Engagement mechanisms coupled to the positioning device are aligned to the predefined path and are configured to exert a clamping force upon the element such that the element is secured and positioned by the positioning device in constant relation to the predefined path as the operations are performed.

Abstract: A method for performing operations on a workpiece. The method comprises the steps of: contacting the workpiece with a tool; moving the tool along any of multiple axes; moving a clamp along at least a first axis independent of the movement of the tool; and, clamping the workpiece using the clamp. Contacting the workpiece with the tool may comprise plunging a friction stir welding pin tool into the workpiece while the workpiece is being clamped. The tool may be moved by moving a spindle housing over the workpiece, and the clamp may be moved by rotating the clamp around the first axis as the spindle housing moves over the workpiece. The method may further comprise the step of coordinating the movement of the clamp with the movement of the tool.

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: A friction stir welding (FSW) apparatus has an FSW tool adapted for joining work pieces supportable against a backing anvil. The FSW apparatus comprises a pair of clamping rollers maintained in substantially perpendicular relationship to the backing anvil as the FSW tool moves along the tool path. A roller pivot joint of the FSW apparatus maintains a cylindrical roller outer surface of each clamping roller in substantially parallel relationship to the top sides of the work pieces. The roller pivot joint may include a gimballing roller bearing to which the clamping roller is mounted. The roller bearing is universally movable in a variety of directions to maintain the perpendicular relationship of the clamping rollers relative to the backing anvil.

Abstract: A counter-rotating spindle includes a shoulder tool, a pin tool inserted in the shoulder tool, a first motor that is connected with the pin tool and rotates the pin tool, and a second motor that is connected with the shoulder tool and rotates the shoulder tool. The direction and the speed of the rotation for the pin tool may be selected independently from the speed and direction of rotation of the shoulder tool enabling optimization of the friction stir welding process. Counter-rotating the pin tool and the shoulder tool may improve the mixing abilities and efficiency of the pin tool and may prevent the galling effect between the pin tool and the shoulder tool. The counter-rotating spindle may be used, for example, for continuous path friction stir welding and spot welding of aluminum and its alloys, including cast alloys, as well as joining similar and dissimilar alloys.

Abstract: A friction stir welding (FSW) apparatus has an FSW tool adapted for joining work pieces supportable against a backing anvil. The FSW apparatus comprises a pair of clamping rollers maintained in substantially perpendicular relationship to the backing anvil as the FSW tool moves along the tool path. A roller pivot joint of the FSW apparatus maintains a cylindrical roller outer surface of each clamping roller in substantially parallel relationship to the top sides of the work pieces. The roller pivot joint may include a gimballing roller bearing to which the clamping roller is mounted. The roller bearing is universally movable in a variety of directions to maintain the perpendicular relationship of the clamping rollers relative to the backing anvil.

Abstract: An apparatus for friction stir welding is described that includes a stationary assembly having a bore therethrough, the bore having an inner diameter, and a rotational assembly having a welding end. At least the welding end of the rotational assembly extends through the bore. A portion of the rotational assembly is adjacent the inner diameter of the bore. At least one of the adjacent portion of the rotational assembly and the inner diameter of the stationary assembly are configured such that rotation of the rotational assembly will cause plasticized material from a welding process that has entered an area between the adjacent portion and the inner diameter to move towards a welding zone located proximate the welding end.

Abstract: The disclosure provides for a friction stir welding tool cleaning method and apparatus for fixed and retractable pin tools. The method and apparatus use a heating component, a temperature indicator component, a controller component, and a rotatable tool cleaner component for cleaning fixed pin tools. An additional bore cleaner component is used for cleaning retractable pin tools. Heat is applied to a friction stir welding tool having a surface with weld process residue material until the process residue material is sufficiently plasticized, and then the tool cleaner component is applied to the heated tool to remove the plasticized residue on the pin and shoulder surfaces of the tool, and for retractable pin tools, the bore cleaner component is applied to the heated tool to remove the plasticized residue in the tool bore.

Abstract: A friction stir welding apparatus has a novel tool-in-tool construction where a friction stir welding pin tool extends through a center bore of a friction stir welding shoulder tool and is moveable axially and rotationally relative to the shoulder tool. The pin tool and shoulder tool both have their own dedicated tool holders and spindles that enable the tools to rotate and move axially relative to each other and enable easy replacement of each of the tools.

Abstract: The invention is directed to a friction stir welding tool cleaning method and apparatus for fixed and retractable pin tools. The method and apparatus use a heating component, a temperature indicator component, a controller component, and a rotatable tool cleaner component for cleaning fixed pin tools. An additional bore cleaner component is used for cleaning retractable pin tools. Heat is applied to a friction stir welding tool having a surface with weld process residue material until the process residue material is sufficiently plasticized, and then the tool cleaner component is applied to the heated tool to remove the plasticized residue on the pin and shoulder surfaces of the tool, and for retractable pin tools, the bore cleaner component is applied to the heated tool to remove the plasticized residue in the tool bore.

Abstract: An apparatus and method are provided for measuring loads on a rotating friction stir welding tool of a friction stir welding machine. The apparatus includes a frame that can be connected to the friction stir welding machine, and rollers rotatably connected to the frame are structured to contact and rotate with the friction stir welding tool. Each roller is adapted to adjust in a respective direction and communicate with a respective load cell so that the load cells detect a positional characteristic of the rollers and measure loads applied to the rotating friction stir welding tool during operation. The rollers can contact the rotating tool directly during operation of the machine, such as while the rotating tools is being moved through a workpiece to form a friction stir weld joint, to measure the loads on the tool in the direction of movement of the tool and a direction normal to the movement, i.e., the path and path normal directions.

Abstract: A friction stir welding (FSW) apparatus has an FSW tool adapted for joining work pieces supportable against a backing anvil. The FSW apparatus comprises a pair of clamping rollers maintained in substantially perpendicular relationship to the backing anvil as the FSW tool moves along the tool path. A roller pivot joint of the FSW apparatus maintains a cylindrical roller outer surface of each clamping roller in substantially parallel relationship to the top sides of the work pieces. The roller pivot joint may include a gimballing roller bearing to which the clamping roller is mounted. The roller bearing is universally movable in a variety of directions to maintain the perpendicular relationship of the clamping rollers relative to the backing anvil.

Abstract: An apparatus for friction stir welding is described that includes a stationary assembly having a bore therethrough, the bore having an inner diameter, and a rotational assembly having a welding end. At least the welding end of the rotational assembly extends through the bore. A portion of the rotational assembly is adjacent the inner diameter of the bore. At least one of the adjacent portion of the rotational assembly and the inner diameter of the stationary assembly are configured such that rotation of the rotational assembly will cause plasticized material from a welding process that has entered an area between the adjacent portion and the inner diameter to move towards a welding zone located proximate the welding end.

Abstract: A counter-rotating spindle includes a shoulder tool, a pin tool inserted in the shoulder tool, a first motor that is connected with the pin tool and rotates the pin tool, and a second motor that is connected with the shoulder tool and rotates the shoulder tool. The direction and the speed of the rotation for the pin tool may be selected independently from the speed and direction of rotation of the shoulder tool enabling optimization of the friction stir welding process. Counter-rotating the pin tool and the shoulder tool may improve the mixing abilities and efficiency of the pin tool and may prevent the galling effect between the pin tool and the shoulder tool. The counter-rotating spindle may be used, for example, for continuous path friction stir welding and spot welding of aluminum and its alloys, including cast alloys, as well as joining similar and dissimilar alloys.

Abstract: An apparatus for friction stir welding is described that includes a stationary assembly having a bore therethrough, the bore having an inner diameter, and a rotational assembly having a welding end. At least the welding end of the rotational assembly extends through the bore. A portion of the rotational assembly is adjacent the inner diameter of the bore. At least one of the adjacent portion of the rotational assembly and the inner diameter of the stationary assembly are configured such that rotation of the rotational assembly will cause plasticized material from a welding process that has entered an area between the adjacent portion and the inner diameter to move towards a welding zone located proximate the welding end.

Abstract: A portable multi-axis load confirmation tool having a rotating ball on the end thereof follows a three-dimensional weld program path therewith. The ball reacts to an internal load cell for verifying weld program path dynamics before an actual program is run with friction stir welding tools. The load cell is connected to instrumentation electronics converting a load cell signal to a digital readout and comparing the load cell signal to weld program load requirements. The tool integrates into a tool holder loaded on a friction stir welding spindle for simulating an actual friction stir welding tool.

Abstract: An apparatus and method are provided for measuring loads on a rotating friction stir welding tool of a friction stir welding machine. The apparatus includes a frame that can be connected to the friction stir welding machine, and rollers rotatably connected to the frame are structured to contact and rotate with the friction stir welding tool. Each roller is adapted to adjust in a respective direction and communicate with a respective load cell so that the load cells detect a positional characteristic of the rollers and measure loads applied to the rotating friction stir welding tool during operation. The rollers can contact the rotating tool directly during operation of the machine, such as while the rotating tools is being moved through a workpiece to form a friction stir weld joint, to measure the loads on the tool in the direction of movement of the tool and a direction normal to the movement, i.e., the path and path normal directions.