Abstract: A method of making an aerofoil blink comprising a plurality of aerofoil blades joined to a disc to extend radially outwardly therefrom is provided. The method includes the step of: (a) modelling a linear friction welding process in which a blade member is joined to the disc, the blade member having a stub for joining to the disc, wherein the modelling provides results which are indicative of the welding power at positions along the stub during the welding process; (b) identifying adaptations to the stub using the modelling results to compensate for differences in welding power along the stub during the welding process; (c) providing a blade member having a stub with the identified adaptations; and (d) joining the provided blade member to the disc by the linear friction welding process.

Abstract: A method of linear friction welding, the method comprising: a friction phase comprising oscillating a first workpiece (2) relative to a second workpiece (4) with a surface of the first workpiece (2) being forced against a surface of the second workpiece (4), such that a plasticised layer is formed at the interface between the first and second workpieces (2, 4); wherein the friction phase is divided into a plurality of sub-phases, each sub-phase being configured to form a plasticised layer at the interface between the first and second workpieces (2, 4), each plasticised layer comprising a stagnation zone (10a, 10b); wherein the stagnation zone (10a) of one sub-phase is offset from the stagnation zone (10b) of another sub-phase.

Abstract: A method of determining the quality of a friction weld between two components, the method comprising joining two components together using a friction welding process, measuring the loss of length of the components as a function of time during the friction welding process, determining the double differential with respect to time of the loss in length of the components as a function of time, determining the quality of the friction weld by calculating the R2 value of the linear fit to the loss in length of the components as a function of time over a defined time period, determining the end of the defined time period by identifying the start of the final positive peak of the double differential with respect to time of the loss of length of the components as a function of time, calculating R2 from the least square difference of the linear fit over the defined time period of the loss of length of the components as a function of time and comparing the calculated value of R2 with acceptable values of R2 to determine

Abstract: A weld enclosure and welding apparatus including a weld enclosure. Also a method of welding. The apparatus has first and second opposed tooling faces adapted to receive and hold respective first and second weld elements. The weld enclosure comprises a housing that allows relative movement between the weld elements and a change in a physical dimension of at least one of the weld elements. The weld enclosure also comprises locating means for locating the housing relative to the welding apparatus and includes heating means.

Abstract: A method of friction welding comprises providing a first workpiece having a first weld surface and a second workpiece having a second weld surface. The first workpiece is arranged such that it tapers away from the first weld surface, the first workpiece converges in a direction away from the first weld surface. The first and second workpieces are arranged such that the first weld surface abuts the second weld surface. The first and second workpieces are oscillated relative to each other such that at least one of the weld surfaces of at least one of the workpieces moves relative to the other weld surface of the other workpiece such that the temperature increases at the weld surfaces to create a weld interface. The oscillation is stopped and the first and second weld surfaces are allowed to cool to weld the first and second workpieces together.

Abstract: A method of making an aerofoil blink comprising a plurality of aerofoil blades joined to a disc to extend radially outwardly therefrom is provided, The method includes the step of: (a) modelling a linear friction welding process in which a blade member is joined to the disc, the blade member having a stub for joining to the disc, wherein the modelling provides results which are indicative of the welding power at positions along the stub during the welding process; (b) identifying adaptations to the stub using the modelling results to compensate for differences in welding power along the stub during the welding process; (c) providing a blade member having a stub with the identified adaptations; and (d) joining the provided blade member to the disc by the linear friction welding process.

Abstract: A method of determining the quality of a friction weld between two components, the method comprising joining two components together using a friction welding process, measuring the loss of length of the components as a function of time during the friction welding process, determining the double differential with respect to time of the loss in length of the components as a function of time, determining the quality of the friction weld by calculating the R2 value of the linear fit to the loss in length of the components as a function of time over a defined time period, determining the end of the defined time period by identifying the start of the final positive peak of the double differential with respect to time of the loss of length of the components as a function of time, calculating R2 from the least square difference of the linear fit over the defined time period of the loss of length of the components as a function of time and comparing the calculated value of R2 with acceptable values of R2 to determine

Abstract: A method is disclosed for controlling a process in which a component 4 is moved relative to another component 6 such that at least one of the components 4, 6 experiences a reduction in magnitude in at least one dimension. Such processes may include for example friction welding. The method comprises monitoring energy input to the process and adjusting an input parameter for the process based on the monitored energy input. The monitoring of energy input is performed before any reduction in component magnitude has begun to take place.

Abstract: A method of friction welding comprising providing a first workpiece (24) having a first weld surface (38) and a second workpiece (26) having a second weld surface (40). In a first region (42) adjacent the first weld surface (38) the first workpiece (24) is arranged at an angle (?) of substantially 90° to the first weld surface (38) and in a second region (44) adjacent to the first region (42) the first workpiece (24) tapers away from the first weld surface (38). The first workpiece (24) is arranged such that in the second region (44) the first workpiece (24) is arranged at an angle (?) greater than 90° and less than 180° to the first weld surface (38). The first and second workpieces (24, 26) are arranged such that first weld surface (38) of the first workpiece (24) abuts the second weld surface (40) of the second workpiece (26).

Abstract: A method of friction welding comprising providing a first workpiece (24) having a first weld surface (38) and a second workpiece (26) having a second weld surface (40). In a first region (42) adjacent the first weld surface (38) the first workpiece (24) is arranged at an angle (?) of substantially 90° to the first weld surface (38) and in a second region (44) adjacent to the first region (42) the first workpiece (24) tapers away from the first weld surface (38). The first workpiece (24) is arranged such that in the second region (44) the first workpiece (24) is arranged at an angle (?) greater than 90° and less than 180° to the first weld surface (38). The first and second workpieces (24, 26) are arranged such that first weld surface (38) of the first workpiece (24) abuts the second weld surface (40) of the second workpiece (26).

Abstract: A blade member is oscillated in the direction of arrow A-A relative to a rim of a disc; a forge force is applied radially and a weld is formed along line; the blade member is formed from a face centred cubic (FCC) nickel based single crystal alloy, such as CMSX-4 of Cannon-Muskegon Corporation; the orientation of the single crystal blade member is controlled to maximize the stress on the slip plane; by maximizing the stress on the slip plane the in-plane friction forces and the forge force are minimized; minimizing the in-plane forces enables the single crystal blade member to be successfully welded to the rim of the disc.

Abstract: A weld enclosure (15) and welding apparatus (10) including a weld enclosure (15). Also a method of welding. The apparatus (10) has first (12) and second (14) opposed tooling faces adapted to receive and hold respective first (16) and second (18) weld elements. The weld enclosure (15) comprises a housing (22, 24a, 24b) that allows relative movement between the weld elements (16, 18) and a change in a physical dimension of at least one of the weld elements (16, 18). The weld enclosure (15) also comprises locating means for locating the housing (22, 24a, 24b) relative to the welding apparatus and includes heating means (20).

Abstract: A method of friction welding comprises providing a first workpiece (24) having a first weld surface (38) and a second workpiece (26) having a second weld surface (40). The first workpiece (24) is arranged such that it tapers away from the first weld surface (38), the first workpiece (24) converges in a direction away from the first weld surface (38). The first and second workpieces (24, 26) are arranged such that the first weld surface (38) abuts the second weld surface (40). The first and second workpieces (24, 26) are oscillated relative to each other such that at least one of the weld surfaces (38, 40) of at least one of the workpieces (24, 26) moves relative to the other weld surface (40, 38) of the other workpiece (26, 24) such that the temperature increases at the weld surfaces (38, 40) to create a weld interface (42). The oscillation is stopped and the first and second weld surfaces (38, 40) are allowed to cool to weld the first and second workpieces (24, 26) together.

Abstract: A blade member is oscillated in the direction of arrow A-A relative to a rim of a disc; a forge force is applied radially and a weld is formed along line; the blade member is formed from a face centred cubic (FCC) nickel based single crystal alloy, such as CMSX-4 of Cannon-Muskegon Corporation; the orientation of the single crystal blade member is controlled to maximize the stress on the slip plane; by maximizing the stress on the slip plane the in-plane friction forces and the forge force are minimized; minimizing the in-plane forces enables the single crystal blade member to be successfully welded to the rim of the disc.

Abstract: A friction welding process providing a workpiece having a weld surface, and a second workpiece having a weld surface. The workpieces being welded together at respective weld surfaces. Oscillatory motion is affected to the workpieces such that one weld surface moves across the other, thereby raising the temperature at the weld surfaces to create a weld interface. The oscillatory motion is ceased and the weld surfaces cool to weld the workpieces together at the interface. The workpiece has an extending portion, and the weld surface is provided on the extending portion. The extending portion includes an apex region, which engages the second workpiece's weld surface. A side face extends from the apex region to provide a gap between the side face and the second workpiece's weld surface. The gap allows weld flash material to pass from the weld interface through said gap.

Abstract: A method of making an aerofoil blisk (10) comprising a plurality of aerofoil blades (12) joined to a disc (14) to extend radially outwardly therefrom includes the step of forming a blade member (28) having a stub (30) for joining to the disc (14), the stub (30) having a taper ratio of less than 2. The stub (30) of the blade member (28) may be joined to the disc (14) by linear friction welding, and excess material may subsequently be machined from the blade member (28) to form the blade (12).