Abstract: One example of the present disclosure relates to a method of processing first and second workpieces. The method includes constraining the second workpiece; abutting first and second workpieces together to form a joint; applying first and second selectively adjustable forces against the first workpiece to bias the first workpiece against the second workpiece; friction stir welding the first and second workpieces along the joint; maintaining the forces equal to each other while friction stir welding; and automatically varying at least one of the forces responsive to thermal size variations of the first and second workpieces. An apparatus for carrying out this method is also provided.

Abstract: A manufacturing apparatus is presented. The manufacturing apparatus comprises a tool support movable along multiple axes; a tool mounted on the tool support for performing a manufacturing operation on a workpiece; and an ancillary device releasably mounted on the tool support and used in conjunction with the tool, the ancillary device moveable along at least a first axis independent of the movement of the tool.

Abstract: One example of the present disclosure relates to a method of processing first and second workpieces. The method includes constraining the second workpiece; abutting first and second workpieces together to form a joint; applying first and second selectively adjustable forces against the first workpiece to bias the first workpiece against the second workpiece; friction stir welding the first and second workpieces along the joint; maintaining the forces equal to each other while friction stir welding; and automatically varying at least one of the forces responsive to thermal size variations of the first and second workpieces. An apparatus for carrying out this method is also provided.

Abstract: One example of the present disclosure relates to a method of processing first and second workpieces. The method includes constraining the second workpiece; abutting first and second workpieces together to form a joint; applying first and second selectively adjustable forces against the first workpiece to bias the first workpiece against the second workpiece; friction stir welding the first and second workpieces along the joint; maintaining the forces equal to each other while friction stir welding; and automatically varying at least one of the forces responsive to thermal size variations of the first and second workpieces. An apparatus for carrying out this method is also provided.

Abstract: One example of the present disclosure relates to a method of processing first and second workpieces. The method includes constraining the second workpiece; abutting first and second workpieces together to form a joint; applying first and second selectively adjustable forces against the first workpiece to bias the first workpiece against the second workpiece; friction stir welding the first and second workpieces along the joint; maintaining the forces equal to each other while friction stir welding; and automatically varying at least one of the forces responsive to thermal size variations of the first and second workpieces. An apparatus for carrying out this method is also provided.

Abstract: A reconfigurable clamping system is disclosed. An example clamping system for securing a workpiece comprises a retention assembly and an inflatable bladder. The retention assembly comprises a plurality of links, each pair of adjacent links having a pivotal connection to enable the retention assembly to be configured to the general shape of a workpiece, and each pair of adjacent links having a locking mechanism to selectively lock an angular relationship between the pair. The inflatable bladder is coupled between the retention assembly and the workpiece and is to apply a clamping force to the workpiece.

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 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 reconfigurable clamping system is disclosed. An example clamping system for securing a workpiece comprises a retention assembly and an inflatable bladder. The retention assembly comprises a plurality of links, each pair of adjacent links having a pivotal connection to enable the retention assembly to be configured to the general shape of a workpiece, and each pair of adjacent links having a locking mechanism to selectively lock an angular relationship between the pair. The inflatable bladder is coupled between the retention assembly and the workpiece and is to apply a clamping force to the workpiece.

Abstract: A manufacturing apparatus is presented. The manufacturing apparatus comprises a tool support movable along multiple axes; a tool mounted on the tool support for performing a manufacturing operation on a workpiece; and an ancillary device releasably mounted on the tool support and used in conjunction with the tool, the ancillary device moveable along at least a first axis independent of the movement of the tool.

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 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: 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 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 tool-in-tool device driven by a single power spindle performs multiple operations on a workpiece. The device includes a first tool holder for holding a tool such as a drill, and a second tool holder surrounding mounted on the first tool holder. The second tool holder may hold a second tool such as clamp for clamping the drill to the workpiece, a guide bushing for guiding the drill and a chip breaker for breaking workpiece chips generated by a drilling operation. Multiple interchangeable bushings allow matching the bushing to the size of the drill.

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 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: 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 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 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.