Abstract: A method of joining or repairing metal surface structures. Joinder and/or repair of metal or metal-polymer laminate panels may be carried out using so-called “cold metal transfer” gas metal arc welding techniques. Moreover, suitable zinc-copper-aluminum alloys may improve weldability, durability and strength. The reduced thermal input permits effective weld formation at the metal sheet layers without giving rise to temperature gradient sufficient to significantly damage the interior elements.

Abstract: A process for adjoining materials by friction stir welding. Two adjacent material segments are heated by localized heating to raise the temperature of each segment along the intersection to a discrete predefined level below the melting point of the particular segment of material being heated. In conjunction with this discrete localized heating, friction stir welding is carried out along the intersection to form the solid state bond.