Abstract: Disclosed herein are systems, methods, and devices for repairing holes in weld seams created by bobbin friction stir welding tools. A hole may be created when a welding tool or, more specifically, a pin of the tool is removed or otherwise extracted from a weld seam created by the tool. The method may involve inserting a plug (e.g., a rivet) into the hole, reshaping the plug in the hole (e.g., riveting) thereby securing the plug in the component, and creating another weld seam through the plug thereby consuming the plug. In some embodiments, the hole may be reshaped prior to inserting the plug. For example, the hole may be drilled out and/or a countersink may be created on one or both ends of the hole. Furthermore, the plug may extend outside of the hole prior to its reshaping and, in some embodiments, even after reshaping.

Abstract: Disclosed herein are systems, methods, and devices for repairing holes in weld seams created by bobbin friction stir welding tools. A hole may be created when a welding tool or, more specifically, a pin of the tool is removed or otherwise extracted from a weld seam created by the tool. The method may involve inserting a plug (e.g., a rivet) into the hole, reshaping the plug in the hole (e.g., riveting) thereby securing the plug in the component, and creating another weld seam through the plug thereby consuming the plug. In some embodiments, the hole may be reshaped prior to inserting the plug. For example, the hole may be drilled out and/or a countersink may be created on one or both ends of the hole. Furthermore, the plug may extend outside of the hole prior to its reshaping and, in some embodiments, even after reshaping.

Abstract: Disclosed herein are systems, methods, and devices for repairing holes in weld seams created by bobbin friction stir welding tools. A hole may be created when a welding tool or, more specifically, a pin of the tool is removed or otherwise extracted from a weld seam created by the tool. The method may involve inserting a plug (e.g., a rivet) into the hole, reshaping the plug in the hole (e.g., riveting) thereby securing the plug in the component, and creating another weld seam through the plug thereby consuming the plug. In some embodiments, the hole may be reshaped prior to inserting the plug. For example, the hole may be drilled out and/or a countersink may be created on one or both ends of the hole. Furthermore, the plug may extend outside of the hole prior to its reshaping and, in some embodiments, even after reshaping.

Abstract: Disclosed herein are systems, methods, and devices for repairing holes in weld seams created by bobbin friction stir welding tools. A hole may be created when a welding tool or, more specifically, a pin of the tool is removed or otherwise extracted from a weld seam created by the tool. The method may involve inserting a plug (e.g., a rivet) into the hole, reshaping the plug in the hole (e.g., riveting) thereby securing the plug in the component, and creating another weld seam through the plug thereby consuming the plug. In some embodiments, the hole may be reshaped prior to inserting the plug. For example, the hole may be drilled out and/or a countersink may be created on one or both ends of the hole. Furthermore, the plug may extend outside of the hole prior to its reshaping and, in some embodiments, even after reshaping.

Abstract: Systems, methods, and devices are disclosed herein that repair and fill exit holes created by welding operations on vehicle components or parts. Methods may include inserting a plug into the exit hole in one or more vehicle parts, where the exit hole is created by the welding operation performed on the one or more vehicle parts. Methods may further include positioning a first pin on the plug such that the first pin is contacting an exposed surface of the plug, and rotating the first pin while contacting the exposed surface of the plug, where the rotating generates thermal energy based on a frictional force associated with the first pin and the plug. The methods may also include filling the exit hole by heating and plasticizing the plug via the thermal energy, and consolidating a material of the plug with the one or more vehicle parts.

Abstract: Systems, methods, and devices are disclosed herein that repair and fill exit holes created by welding operations on vehicle components or parts. Methods disclosed herein may include inserting a plug into an exit hole in one or more vehicle parts, where the exit hole is created by a welding operation performed on the one or more vehicle parts. Methods may also include positioning a shoulder member on the plug such that the shoulder member is contacting an exposed surface of the plug. Methods may further include rotating the shoulder member while contacting the exposed surface of the plug, the rotating generating thermal energy based on a frictional force associated with the shoulder member and the plug. Methods may also include filling the exit hole by heating and plasticizing the plug via the thermal energy, and consolidating a material of the plug with the one or more vehicle parts.