Abstract: A method of evaluating defects in a friction stir welded seam is provided, the method including: providing a welded sheet of metallic stock, the sheet having a top edge and a bottom edge, opposed side edges, and a joining seam formed between the opposed side edges by means of friction stir welding; isolating a preselected test specimen from the sheet of welded metallic stock, the specimen comprising either the top edge or the bottom edge and a test portion of the seam, with the test portion extending from an intermediate point to either the top or bottom edge and having a longitudinal axis, so that said test portion is disposed perpendicularly to the longitudinal axis, thereby establishing a test specimen face and a weld root; and detaching the specimen from the sheet and then testing the integrity of said weld root.

Abstract: A system and method for joining curved surfaces such as pipes by obtaining pipes having additional rough stock material on the pipe ends, the rough stock material being precision machine processed to prepare complementary face profiles on each of the curved surfaces and then performing friction stir joining of the pipes to obtain a joint that has fewer defects than joints created from conventional welding.

Abstract: A method is taught for creating a hollow sphere that is created by joining two cylinders together that have a semispherical hollow formed in the ends being joined together, wherein a metallic reinforcing disk is inserted at an interface between the two ends of the cylinders, wherein the two cylinders and reinforcing disk are joined using friction stir welding to create an inner sphere from the two hemispherical hollows that is bisected by the metallic reinforcing disk, and wherein the joined cylinders and reinforcing disk are machined to thereby create an outer spherical surface that is centered around the inner sphere.

Abstract: A method is taught for creating a hollow sphere that is created by joining two cylinders together that have a semispherical hollow formed in the ends being joined together, wherein a metallic reinforcing disk is inserted at an interface between the two ends of the cylinders, wherein the two cylinders and reinforcing disk are joined using friction stir welding to create an inner sphere from the two hemispherical hollows that is bisected by the metallic reinforcing disk, and wherein the joined cylinders and reinforcing disk are machined to thereby create an outer spherical surface that is centered around the inner sphere.

Abstract: A method is taught for creating a hollow sphere that is created by joining two cylinders together that have a semispherical hollow formed in the ends being joined together, wherein a metallic reinforcing disk is inserted at an interface between the two ends of the cylinders, wherein the two cylinders and reinforcing disk are joined using friction stir welding to create an inner sphere from the two hemispherical hollows that is bisected by the metallic reinforcing disk, and wherein the joined cylinders and reinforcing disk are machined to thereby create an outer spherical surface that is centered around the inner sphere.

Abstract: Metallic materials may be joined utilizing a friction stir processing technique. The friction stir processing technique utilizes a shaped, rotating tool to move material from one side of the joint to be welded to the other without liquefying the base material.

Abstract: A rotatable tool for friction stir welding a workpiece and an associated apparatus and method are provided. The tool includes a first pin portion that extends from a shoulder and defines a contour surface opposite the shoulder. A second pin portion extends from the contour surface of the first pin portion. The contour surface, which mixes the material of the workpiece during welding, can increase the mixing of the material at the interface, thereby increasing the strength of the joint.

Abstract: Friction stir processing (FSP) provides a hardened golf club face that more efficiently transfers momentum between the golf club and the ball, increasing the launch velocity so as to provide increased loft (for a given distance traveled by the ball). The FSP hardened face is also more resistant to wear so that the golf club provides more consistent performance and lasts longer. A practice club having a friction stir processed sweet spot on the face may enable the golfer to feel whether the ball has been hit by the sweet spot.

Abstract: The method of this invention for assembling vehicle brake shoes includes the use of linear friction welding. Two generally planar web members having arcuate edges are precisely aligned. Each of the web members preferably includes a series of projections along an outer arcuate edge. A table member that has a curvature corresponding to the outward arcuate edge of the web members is placed in contact with the projections along the outer arcuate edge of the web members. The webs and the table are moved relative to each other, under load, to cause an increase in temperature within the metal material of the webs and the table. After the temperature is sufficiently increased, but before the material reaches its melting temperature, the relative motion is stopped and the web members are precisely aligned with the table member. Then the load is increased and the table is forced against the web members. The projections are then deformed, a flash results, and the web members are fixedly joined to the table member.

Abstract: A method of forming vehicle wheel rims includes utilizing linear friction welding. A generally planar piece of metal material is placed into a coil position with two ends in abutment. The abutting ends are oscillated or moved, in a generally linear pattern, relative to each other to increase the temperature of the metal at each end. After the temperature has been increased sufficiently, without reaching the melting temperature of the metal, the linear motion is stopped. The ends are then aligned precisely and forced together with an increased axial load. After cooling, the two ends are permanently joined together with an essentially defect-free welded joint.