Abstract: A method for manufacturing a tool having one or more internal channels includes forming one or more channel cores by additive manufacturing, coating a metal onto the one or more channel cores to form a metal tube on each of the one or more channel cores, positioning the one or more metal tubes into a casting mold having a shape of a tool, and casting a molten metal into the casting mold to form the tool having the one or more internal channels corresponding to the one or more channel cores.

Abstract: A thermoplastic welding assembly and method for joining a plurality of thermoplastic support components to a thermoplastic component is provided. The thermoplastic welding assembly includes a frame, a plurality of heat sinks, and a plurality of individually actuatable pressurizers. The frame includes a plurality of welding slots. Each heat sink of the plurality of heat sinks is positioned within one of the welding slots. Each pressurizer of the plurality of individually actuatable pressurizers includes an alignment actuator configured to move one thermoplastic support component into alignment with one welding slot, and a clamping actuator configured to move the one thermoplastic support component into contact with the thermoplastic component. In some implementations, the thermoplastic welding assembly further includes a plurality of actuators configured to move the alignment actuator and the clamping actuator.

Abstract: A thermoplastic welding assembly and method for joining a plurality of thermoplastic support components to a thermoplastic component is provided. The thermoplastic welding assembly includes a frame, a plurality of heat sinks, and a plurality of individually actuatable pressurizers. The frame includes a plurality of welding slots. Each heat sink of the plurality of heat sinks is positioned within one of the welding slots. Each pressurizer of the plurality of individually actuatable pressurizers includes an alignment actuator configured to move one thermoplastic support component into alignment with one welding slot, and a clamping actuator configured to move the one thermoplastic support component into contact with the thermoplastic component. In some implementations, the thermoplastic welding assembly further includes a plurality of actuators configured to move the alignment actuator and the clamping actuator.

Abstract: A method of heating a tool assembly includes the step of joining a first piece of the tool assembly with a second piece of the tool assembly via a first joint portion and a second joint portion. The method further includes the step of inserting a fastener through the first joint portion and the second joint portion of the tool assembly. The method further includes the step of applying heat to the tool assembly, wherein upon heating, interlock surfaces of the first joint portion and the second joint portion tighten against each other.

Abstract: A thermoplastic welding assembly includes a structural cage that supports a press and one or more hydraulic and pneumatic actuators. The press includes first and second plates that movable toward and away from each other to load and remove thermoplastic components to be held together for thermoplastic welding. Specifically, the first plate of the press includes non-conductive tooling inserts that are positioned to form a slot for a welding prove, and the second plates includes non-conductive tooling inserts that form cavities for plungers to move through. Plungers that are movable using the actuators are positioned in the cavities of the second plate, and compressible pressurizers are attached to the ends of the plungers. An operator uses electrical controls to move the plungers in the plunger cavities toward the thermoplastic components in the press to drive the pressurizers into the thermoplastic components and provide stabilizing pressure on the components during welding.

Abstract: A method of heating a tool assembly includes the step of joining a first piece of the tool assembly with a second piece of the tool assembly via a first joint portion and a second joint portion. The method further includes the step of inserting a fastener through the first joint portion and the second joint portion of the tool assembly. The method further includes the step of applying heat to the tool assembly, wherein upon heating, interlock surfaces of the first joint portion and the second joint portion tighten against each other.

Abstract: A tool assembly includes a first piece, a second piece, and a fastener. The first piece has a first joint portion including a top surface and at least a first interlock surface. The second piece has a second joint portion configured to interlock with the first joint portion. The second joint portion includes a top surface and at least a second interlock surface that is complementary to the first interlock surface. The fastener extends through the first and second joint portions. The first interlock surface and the top surface of the first joint portion form an obtuse angle corner and the second interlock surface and the top surface of the second joint portion form an acute angle corner. The first interlock surface is configured to contact the second interlock surface to inhibit relative movement between the first piece and the second piece along a longitudinal axis of the tool assembly.

Abstract: A tool assembly includes a first piece, a second piece, and a fastener. The first piece has a first joint portion including a top surface and at least a first interlock surface. The second piece has a second joint portion configured to interlock with the first joint portion. The second joint portion includes a top surface and at least a second interlock surface that is complementary to the first interlock surface. The fastener extends through the first and second joint portions. The first interlock surface and the top surface of the first joint portion form an obtuse angle corner and the second interlock surface and the top surface of the second joint portion form an acute angle corner. The first interlock surface is configured to contact the second interlock surface to inhibit relative movement between the first piece and the second piece along a longitudinal axis of the tool assembly.

Abstract: One aspect of the disclosure relates to a friction stir welding apparatus. The friction stir welding apparatus includes a spindle housing and a pin tool concentric with an axis and rotatable relative to the spindle housing about the axis. The friction stir welding apparatus also includes a first shoulder not substantially rotatable relative to the spindle housing about the axis and a second shoulder not substantially rotatable relative to the spindle housing about the axis. The pin tool is rotatable relative to the first shoulder and the second shoulder.

Abstract: One aspect of the disclosure relates to a friction stir welding apparatus. The friction stir welding apparatus includes a spindle housing and a pin tool concentric with an axis and rotatable relative to the spindle housing about the axis. The friction stir welding apparatus also includes a first shoulder not substantially rotatable relative to the spindle housing about the axis and a second shoulder not substantially rotatable relative to the spindle housing about the axis. The pin tool is rotatable relative to the first shoulder and the second shoulder.

Abstract: One aspect of the disclosure relates to a friction stir welding apparatus. The friction stir welding apparatus includes a spindle housing and a pin tool concentric with an axis and rotatable relative to the spindle housing about the axis. The friction stir welding apparatus also includes a first shoulder not substantially rotatable relative to the spindle housing about the axis and a second shoulder not substantially rotatable relative to the spindle housing about the axis. The pin tool is rotatable relative to the first shoulder and the second shoulder.

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 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: 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 collet clamping nosepiece for a power feed drill is described which includes at least one clamping piston located along a centerline of the nosepiece, an expansion mandrel comprising a frusto-conical exterior surface, and an expandable collet. The expandable collet is configured to substantially surround the expansion mandrel and operatively connect to the at least one clamping piston. Operation of the at least one clamping piston causes the mandrel to move along the exterior surface of the expansion mandrel for engagement and disengagement of the collet with a bore configured for insertion of the collet.

Abstract: A method of mitigating distortion in a friction stir weld joint as well as an associated friction stir weld assembly for mitigating distortion in a friction stir weld joint are provided. In this regard, a workpiece having a friction stir weld joint and associated distortion may be provided. Force may then be selectively applied to the workpiece along at least a portion of friction stir weld joint. The application of force induces plastic deformation along at least the portion of the friction stir weld joint in order to reduce the distortion of the workpiece. Force may be applied, for example, by moving a roller, such as a hardened cylindrical roller having chamfered edges, along at least a portion of the friction stir weld joint in order to apply a compressive force.

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: 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 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.