Abstract: An airfoil component for attaching to a cropped airfoil is provided. The cropped airfoil comprises a cropped airfoil attachment section and a cropped first side opposite a cropped second side, which each extend axially between a cropped first edge and a cropped second edge to define a cropped chord length. The airfoil component comprises a body having a component first side opposite a component second side. The body defines an attachment section for attaching the airfoil component to the cropped airfoil at the cropped airfoil attachment section. The attachment section extends axially between a component first edge and a component second edge to define a component chord length, and the attachment section is oversized with respect to the cropped airfoil attachment section such that the component chord length is longer than the cropped chord length. Systems and methods also are provided.

Abstract: An airfoil component for attaching to a cropped airfoil is provided. The cropped airfoil comprises a cropped airfoil attachment section and a cropped first side opposite a cropped second side, which each extend axially between a cropped first edge and a cropped second edge to define a cropped chord length. The airfoil component comprises a body having a component first side opposite a component second side. The body defines an attachment section for attaching the airfoil component to the cropped airfoil at the cropped airfoil attachment section. The attachment section extends axially between a component first edge and a component second edge to define a component chord length, and the attachment section is oversized with respect to the cropped airfoil attachment section such that the component chord length is longer than the cropped chord length. Systems and methods also are provided.

Abstract: An airfoil component for attaching to a cropped airfoil is provided. The cropped airfoil comprises a cropped airfoil attachment section and a cropped first side opposite a cropped second side, which each extend axially between a cropped first edge and a cropped second edge to define a cropped chord length. The airfoil component comprises a body having a component first side opposite a component second side. The body defines an attachment section for attaching the airfoil component to the cropped airfoil at the cropped airfoil attachment section. The attachment section extends axially between a component first edge and a component second edge to define a component chord length, and the attachment section is oversized with respect to the cropped airfoil attachment section such that the component chord length is longer than the cropped chord length. Systems and methods also are provided.

Abstract: Methods for making near net shape airfoil metal leading edge protective strips including providing a high temperature additive manufacturing device; providing a tooling system having a mandrel; a metallic cladding applied to the mandrel; and at least one cooling channel associated with the mandrel applying a metallic deposit to the mandrel having the metallic cladding using the high temperature additive manufacturing device; and concurrently removing heat from the mandrel using the at least one cooling channel to produce the near net shape airfoil metal leading edge protective strip.

Abstract: Methods for making near net shape airfoil metal leading edge protective strips including providing a high temperature additive manufacturing device; providing a tooling system having a mandrel; a metallic cladding applied to the mandrel; and at least one cooling channel associated with the mandrel applying a metallic deposit to the mandrel having the metallic cladding using the high temperature additive manufacturing device; and concurrently removing heat from the mandrel using the at least one cooling channel to produce the near net shape airfoil metal leading edge protective strip.

Abstract: Composite airfoils including a leading edge, and a near net shape metal leading edge protective strip operably connected to the leading edge, the protective strip made by providing a high temperature additive manufacturing device; providing a tooling system including a mandrel; a metallic cladding; and at least one cooling channel applying a metallic deposit to the mandrel having the metallic cladding using the high temperature additive manufacturing device; and concurrently removing heat from the mandrel using the at least one cooling channel.

Abstract: Tooling systems including a mandrel for receiving, and providing shape to, a metallic deposit applied using a high temperature additive manufacturing device; a metallic cladding applied to the mandrel for reducing contamination of the metallic deposit; and at least one cooling channel associated with the mandrel for removing heat from the system.

Abstract: A method of friction stir welding and a non-consumable retractable shoulderless variable penetration friction stir welding tool. The tool includes a substantially cylindrical body portion, a head portion, and a tip section, each integral to the tool. The body portion has a longitudinal axis about which it is rotable, a diameter, a sidewall substantially parallel to the longitudinal axis, a proximal end, and a distal end. The head portion is located at the distal end of the body portion. The head portion has a base with a diameter substantially equal to the diameter of the body portion thereby forming a smooth transition between the body portion and the head portion, thus the tool has no shoulder. The head portion includes a face that converges to the tip section. The tool is retractable, reduces overheating, improves weld quality by reducing internal voids and lack of fusion, and facilitates variable penetration welds.

Abstract: An apparatus for friction stir welding, a weld tool for friction stir welding, and a method for making a weld tool for friction stir welding are presented. The weld tool comprises doped tungsten. A method for manufacturing an article, where the method comprises providing the apparatus for friction stir welding, and the article produced by this method are also presented.

Abstract: The present invention provides a friction stir welding apparatus operable for welding one or more metals, metal alloys, or other materials. The friction stir welding apparatus includes a pin tool holder, a shoulder having a surface coupled to the pin tool holder, and a pin tool coupled to the pin tool holder, the pin tool at least partially protruding from the surface of the shoulder, wherein the pin tool is made of a consumable pin tool material. Optionally, the shoulder rotates at a predetermined rotational speed and is retractable into/extendable from the pin tool holder at a substantially constant rate. Optionally, the shoulder is also made of a consumable shoulder material that is at least partially incorporated into the volume of a joint to be welded. The consumable shoulder material comprises a material that is the same as, similar to, or dissimilar from one or more materials comprising a workpiece to be friction stir welded.

Abstract: The apparatus (50) includes a friction stir welding tool (100), a local clamping means (200), and an interface (300) that joins the tool (100) and the local clamping means (200). The local clamping means (200) is in close proximity to the at least one sidewall (130) of the tool (100) and has a housing (210) and a plurality of contact devices (220). The local clamping means (200) transfers a clamping force to the first and the second components (C1, C2) and holds them firmly in place during welding. The local clamping means (200) includes a plurality of contact devices (220) that may take the form of casters, rollers (222), and ball bearings (224). The location of the contact devices (220) is significant as external clamping is greatly reduced, and often eliminated, as the contact devices (220) are brought into close proximity to the area of the weld.

Abstract: A method of friction stir welding and a non-consumable retractable shoulderless variable penetration friction stir welding tool. The tool includes a substantially cylindrical body portion, a head portion, and a tip section, each integral to the tool. The body portion has a longitudinal axis about which it is rotable, a diameter, a sidewall substantially parallel to the longitudinal axis, a proximal end, and a distal end. The head portion is located at the distal end of the body portion. The head portion has a base with a diameter substantially equal to the diameter of the body portion thereby forming a smooth transition between the body portion and the head portion, thus, the tool has no shoulder. The head portion includes a face that converges to the tip section. The tool is retractable, reduces overheating, improves weld quality by reducing internal voids and lack of fusion, and facilitates variable penetration welds.

Abstract: An aluminum tubular unit for long-term, leak-free storage of fluids is formed in which an aluminum cap is ultrasonically welded to an end of the aluminum tube. The ultrasonic weld is formed from a device capable of producing a torsional vibration pattern. The ultrasonic welding of the cap to the tube eliminates the use of seals and pins to seal the cap to the tube and further eliminates the need for having a hole in the cap to mechanically couple the respective end cap to the cylindrical tube. Furthermore, since ultrasonic welding does not generate significant heat, highly volatile and flammable fluids can be present within the tube when the caps are ultrasonically welded to the cylindrical body. In addition, one or more fins used may also be welded to the outside diameter of the cylindrical body using a related ultrasonic welding process.

Abstract: A hollow component for gas turbine engine, for example an outlet guide vane, is assembled from a body having at recessed pocket formed therein, and an aerodynamic cover bonded over the pocket. Both the cover and the body are constructed from materials which are not readily fusion weldable. The cover is attached to the body by a solid state bonding process, for example friction stir welding. The hollow component may also be built up from multiple individual components which are bonded to each other by a solid state bonding process such as friction stir welding.

Abstract: A method for repairing defects in a metallic substrate comprising the steps of placing a consumable filler slug in contact with the substrate in the vicinity of the defect; bringing a first electrode and a second electrode in contact with the consumable slug and applying a pressure to the consumable slug; and transmitting electrical current between the electrodes for a period, thereby resistively heating the consumable slug and the metallic substrate resulting in coalescence in a substantially liquid pool that fills the defect. The pool is then cooled to solidification under the pressure of the electrodes. The electrodes are then removed from contact with the consumable slug and excess material may be removed. The consumable slug may be formed as a single unit or multiple sections, and may incorporate sacrificial retainers to add additional defect filling material, retain the pool, and seal the pool from atmosphere.

Abstract: A method for repairing defects in a substrate comprising the steps of placing a consumable filler slug in contact with the substrate in the vicinity of the defect; placing at least one electrically conductive cover sheet in contact with a portion of the consumable filler slug; bringing a first electrode and a second electrode in contact with the at least one cover sheet and applying a force; and transmitting electrical current between the electrodes, thereby resistively heating the at least one cover sheet and conductively heating the consumable slug and a portion of the substrate resulting in coalescence in a substantially liquid pool that fills the defect. The pool is then cooled to solidification under pressure. Alternative embodiments eliminate the need for the conductive cover sheet(s) by utilizing electrodes having increased electrical and thermal resistance. The consumable slug may be formed as a single unit or multiple sections, and may incorporate sacrificial retainers.

Abstract: The present invention provides a friction stir welding apparatus and associated thermal management systems and methods for joining one or more similar or dissimilar materials forming a workpiece along a joint to be welded. The friction stir welding apparatus includes a pin tool apparatus selectively disposed adjacent to and in direct contact with a first surface of the workpiece along the joint to be welded and a heating member disposed adjacent to a second surface of the workpiece along the joint to be welded, the heating member operable for controllably heating at least a portion of the workpiece adjacent to the joint to be welded. The friction stir welding apparatus also includes an annular spindle having an interior portion and an axis, the interior portion of the annular spindle at least partially defining one or more cooling channels, the one or more cooling channels operable for containing a cooling fluid.

Abstract: The present invention provides a friction stir welding apparatus operable for welding one or more metals, metal alloys, or other materials. The friction stir welding apparatus includes a pin tool holder, a shoulder having a surface coupled to the pin tool holder, and a pin tool coupled to the pin tool holder, the pin tool at least partially protruding from the surface of the shoulder, wherein the pin tool is made of a consumable pin tool material. Optionally, the shoulder rotates at a predetermined rotational speed and is retractable into/extendable from the pin tool holder at a substantially constant rate. Optionally, the shoulder is also made of a consumable shoulder material that is at least partially incorporated into the volume of a joint to be welded. The consumable shoulder material comprises a material that is the same as, similar to, or dissimilar from one or more materials comprising a workpiece to be friction stir welded.

Abstract: A friction stir welding (FSW) travel axis load control method and apparatus for controlling a travel axis load applied to a FSW setup during the joining of workpieces by FSW. The method and apparatus recognize that controlling certain attributes of a friction stir welding plasticized region are key to controlling the quality of the resulting weld. This invention controls any of a number of qualities associated with the plasticized region thereby producing welds having improved mechanical and aesthetic properties, as well as extending the life of the FSW tool. The method and apparatus may control the FSW process to obtain a predetermined optimum size of a heat affected zone. The plasticized region may be monitored in a number of ways including, but not limited to, force on the tool, torque applied to the tool, workpiece temperature, plasticized region physical dimension, as well as changing surface characteristics such as color and reflectivity.