Abstract: A joining method of the present invention includes conducting friction-stir-welding of members to be joined, to form a joint; and then conducting melt-welding or resistance-welding of the joint, wherein the friction-stir-welding of members to be joined is conducted while flowing an inert shielding gas, or the melt-welding or resistance-welding of the joint is conducted while applying an ultrasonic wave.

Abstract: This invention provides a configuration of a joint that allows a satisfactory welded joint to be formed with reduced deformation of the joint region when two-face structures (panels) are friction-welded end to end. The panels 31, 32 each have two substantially parallel plates 33, 34 and a third member 35 connecting the two plates 33, 34. The end portions of the plates 33, 34 of one panel 32 are friction-welded to the end portions of the plates 33, 34 of the other panel 32. At least one of the panels has a plate 36 at its end for connecting the plates 33 and 34 and has a rigidity to support a pressing force produced during the friction welding.

Abstract: An impact resistant composite member is for at least one of armor plate and an impact resistant structure. The member comprises a body in plate form and a reinforcement structure located within the body. The body includes a metal alloy having a fine grain size of about 5 microns or less.

Abstract: A method of making a fiber-reinforced component includes: providing a first composite member having a metal matrix with reinforcing fibers distributed therein; providing a second composite member having a metal matrix with reinforcing fibers distributed therein; and joining the first member to the second member by friction stir welding along a predetermined joint path, such that an average volume fraction of the reinforcing fibers within the joint path is substantially the same as an average volume fraction thereof in the composite members before joining. A fiber-reinforced component includes: first and second members each having a metal matrix with reinforcing fibers distributed therein. The first member is bonded to the second member by a solid state bond along a predetermined joint path, such that an average volume fraction of the reinforcing fibers within the joint path is substantially the same as an average volume fraction thereof in remainder of the members.

Abstract: A method of making a fiber-reinforced component includes: providing a first composite member having a thermoplastic matrix with reinforcing fibers distributed therein; providing a second composite member having a thermoplastic matrix with reinforcing fibers distributed therein; and joining the first member to the second member by friction stir welding along a predetermined joint path, such that an average volume fraction of the reinforcing fibers within the joint path is substantially the same as an average volume fraction thereof in the composite members before joining. A fiber-reinforced component includes: first and second members each having a thermoplastic matrix with reinforcing fibers distributed therein. The first member is bonded to the second member by a solid state bond along a predetermined joint path, such that an average volume fraction of the reinforcing fibers within the joint path is substantially the same as an average volume fraction thereof in remainder of the members.

Abstract: A friction stir welding tool 1 includes a rotor 2 to be attached to a rotation-drive section and a probe 3 concentrically provided on a distal end surface of the rotor 2. A provisional joining projection 4 is concentrically provided on a distal end surface of the probe 3. A relation 0.3 D?d?0.8 D is satisfied, where D represents a diameter (mm) of the distal end surface of the probe 3, and d represents a diameter (mm) of the contour of a transverse cross section of the provisional joining projection 4. The provisional joining projection 4 has a length of 0.3 to 2 mm. This friction stir welding tool can improve the work efficiency of friction stir welding and can carry out friction stir welding which is excellent in welding quality after main friction stir welding.

Abstract: Provided are metal structures and methods of forming such structures for use in oil, gas and/or petrochemical applications that are joined with non-ferrous weld metal compositions or a high alloy weld metal compositions. The welded metal structures include two or more segments of ferrous or non-ferrous components, and fusion welds, friction stir welds or a combination thereof bonding adjacent segments of the components together, wherein the welds comprise a non-ferrous weld metal composition or a high alloy weld metal composition that is substantially different from the metal composition of the two or more components. The resultant welded structures exhibit improvements in fatigue resistance, toughness, strain capacity, strength, stress corrosion cracking resistance, and hydrogen embrittlement resistance compared to traditional iron-based weld compositions.

Abstract: It is an object of the invention to reduce mixing of an impurity from a friction stir welding tool, reduce abrasion of the tool, and prevent the tool from being easily broken even though an object to be worked formed by a metal or an alloy having a high melting point of 1350° C. or more is friction-stir-welded. The friction stir welding tool according to the invention can friction-stir-weld a metal or alloy having a high melting point of 1350° C. or more as an object to be worked. At least a portion brought into contact with the object to be worked has a composition containing iridium, containing rhenium, ruthenium, molybdenum, tungsten, niobium, tantalum, rhodium, or two or more of them, and containing zirconium, hafnium, lanthanum, cerium, samarium, gadolinium, scandium, yttrium, or two or more of them, and has a Micro Vickers Hardness of 300 Hv or more.

Abstract: In a first step, friction stir welding is performed, while supplying a filler into a joining portion, in order to prevent the coarsening of crystal grains of metal materials in a subsequent fusion processing. Then, a fusion processing such as MIG welding is performed. The filler to be added to the joining portion includes a substance that does not chemically react with the metal materials and has a melting point higher than a melting point of the metal materials and a substance in which a misfit with the metal materials is within ±15%. As a result, the coarsening of crystal grains by the fusion processing is inhibited and the joint strength can be increased.

Abstract: A friction stir welding system that enables clamping of a pipe to enable friction stir welding around the pipe OD, a movable mandrel that provides a counter-force to the pressure exerted on the outside of a pipe by a tool, and a system for providing friction stir welding and repair inside a nuclear vessel in an underwater environment.

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 for manufacturing aluminium alloy parts with precipitation hardening including friction stir welding of at least two elements made from the same alloy or different alloys, solution heat treatment, and quenching of welded parts, in which the elements are subjected to heat treatment before welding at temperature T for at least 2t1, t1 being defined as the minimum treatment duration at temperature T leading to a specific melting peak energy defined by AED equal to less than 1 J/g. A method according to the invention substantially avoids an increase in the grain size following solution heat treatment after welding. The invention further relates to novel aluminum materials as well as uses therefor.

Abstract: A method of friction stir welding joints with shims and an associated structural assembly is provided. The structural assembly includes one or more skin members that are disposed and friction stir welded to a substructure. A shim is disposed in a space defined by the other members of the assembly, e.g., between adjacent skin members or between a skin member and the substructure. The shim can be friction stir welded to the other members. That is, the adjacent skin members can be connected via the shim, and/or the skin members can be connected to the substructure via the shim. In some cases, the skin members and the substructure are relatively stiff, and the shim substantially fills the space to reduce flexing of the members during the friction stir welding operation.

Abstract: A structural sandwich plate member is provided with at least one stud welded to one or both of the outer plates and extending into the core. The stud may be arc stud welded to the outer plate before formation of the core. Alternatively, the stud may be installed after formation of the core by drilling a hole in one outer plate and friction welding the stud to one or both outer plates.

Abstract: Provided are stir-welded rotors and methods of making these. An exemplary stir-welded rotor may include a stack of laminations that each has spaced-apart slots arrayed on an outer circumference. The slots register with slot bars that each has a first extremity extending above the stack of laminations and a second extremity extending below the stack of laminations. A first weld extends between first extremities of adjacent slot bars, and a second stir weld extending between adjacent second extremities of adjacent slot bars.

Abstract: The present invention is a cooling plate including a groove, which becomes a passage of a coolant, inside a body, wherein one or more fins are provided inside the groove, wherein the groove is covered with a lid having width larger than the groove, wherein the lid is joined to the body by friction stir welding, and wherein a weld bead formed by: the joining is outside the passage, and the weld bead formed by the joining is formed within the body and further, is characterized by a manufacturing method of a cooling plate that has a first groove, which becomes a passage of a coolant, and a second groove, which has width larger than the first groove and receives a lid on the first groove, inside a body, receives the lid on the second groove, and is joined to the body, the manufacturing method of a cooling plate wherein, while the lid and the body are joined together by the friction stir welding owing to insertion of a-rotation tool having a shoulder and a pin, the joining is performed so that a weld bead formed b

Abstract: Device for joining faces of parts having great longitudinal extension by friction welding. The device includes first and second clamping arrangements structured and arranged to position ends of the parts against one another. At least one of the first and second clamping arrangements are axially movable with respect to another of the first and second clamping arrangements. At least one of the first and second clamping arrangements are movable along a direction that is parallel to a part cross-sectional plane, whereby the part cross-sectional plane is define by an end face of one of the parts. This Abstract is not intended to define the invention disclosed in the specification, nor intended to limit the scope of the invention in any way.

Abstract: A method of forming a sputtering target assembly and the sputtering target assembly made therefrom are described. The method includes bonding a sputtering target to a backing plate at a low temperature. Also described is a method of forming a sputtering target assembly such that a gap is formed between the sputtering target and the backing plate. Also described is a method of forming a sputtering target assembly providing a mechanism to prevent unintended sputtering into the backing plate.

Abstract: A hollow structure, and a method of forming the hollow structure, where the hollow structure includes first and second metal parts, the second metal part having an interior surface and a tapered support member extending from the interior surface. The hollow structure also includes a friction stir welded joint that extends through the first metal part and into the tapered support member.

Abstract: A structure and a method of forming the structure in high temperature sections of next generation nuclear and solar power plants where the structure consists of piping, ducting and enclosures fabricated from oxide dispersion strengthened (ODS) alloys joined by friction stir welding (FSW) to other ODS alloys or any alloy.

Abstract: A welded structure that includes first and second metal parts derived from Al-RE-TM alloys, which are secured together at a welded joint by friction stir welding.

Abstract: A linear friction welding head apparatus for dual axis forging, the apparatus including three sets of orthogonal actuators for providing X-, Y-, and Z-planes of apparatus movement for providing Y-axis oscillation, a first forge load along a first forge axis, and a second forge load along a second forge axis. A method for dual axis forging for welding including providing a welding head for applying first and second forge loads along X- and Z-forge axes to weld at more than one interface. The forge loads may be applied at right angles to each other and have magnitudes corresponding to weld interface length.

Abstract: The present invention provides a tool for forming a friction stir weld joint in a workpiece. According to one embodiment, the tool includes a rotatable pin having first and second ends and defining a stirring portion therebetween structured to frictionally engage the workpiece so as to at least partially form the friction stir weld joint. The tool includes a rotatable first shoulder defining an aperture therethrough structured to slidably receive the first end of the pin. The tool also includes a second shoulder defining an aperture structured to receive the second end of the pin such that the pin extends between the first and second shoulders and such that the second shoulder is in rotatable communication with the pin. The first shoulder is structured to rotate independently of the pin and the second shoulder.

Abstract: Adaptable spring force clamping apparatus and methods are disclosed. In one embodiment, an apparatus includes at least one elongated member adapted to be positioned proximate to a surface of a work piece. The elongated member includes first and second end portions adapted to be secured to substantially prevent movement of the elongated member relative to the surface. A plurality of pressure applying devices are operatively attached to the elongated member, each pressure applying device including a contact member moveable relative to the elongated member and adapted to engage the surface of the work piece, and a resilient member operatively coupled to the contact member and to the elongated member.

Abstract: The present invention provides a tool for forming a friction stir weld joint in a workpiece. According to one embodiment, the tool includes a rotatable pin having first and second ends and defining a stirring portion therebetween structured to frictionally engage the workpiece so as to at least partially form the friction stir weld joint. The tool includes a rotatable first shoulder defining an aperture therethrough structured to slidably receive the first end of the pin. The tool also includes a second shoulder defining an aperture structured to receive the second end of the pin such that the pin extends between the first and second shoulders and such that the second shoulder is in rotatable communication with the pin. The first shoulder is structured to rotate independently of the pin and the second shoulder.

Abstract: A friction-stir tool including a rotary-drivable tool body, at whose end facing away from the drive is provided a shoulder, from which extends in the direction of that end of the tool body that faces away from the drive, a rotatable rod-shaped projection that has a smaller diameter than the shoulder. The surface of the shoulder that points in the direction of the projection is form-adaptable.

Abstract: Catalytic converter (2) includes a catalyst container (10) formed from a tubular blank (10?) and having a catalyst carrier, and a flange member (11) joined to the hollow member. The tubular blank (10?) is subjected to a spinning operation by forming roll or rolls (22A), to form the catalyst container (10) having a desired shape, and the opposed circumferential surfaces of the catalyst container (10) and flange member (11) are forced against each other by the forming roll or rolls (22A) or an array of presser pieces (22B) while the catalyst container and flange member are rotated relatively to each other, so that friction heat is generated for friction-welding the catalyst container and flange member at their joining portions (10b, 11b).

Abstract: A deposition friction stir weld process of joining work pieces includes placing a filler material on and about a joint line formed by butting a first work piece surface against a second work piece surface; and frictionally heating the filler material to soften the filler material and portions of the first and second work piece surfaces in thermal contact with the filler material and form a weld between the first and second work pieces, wherein frictionally heating is at a temperature below a melting point of the filler material and the first and second workpiece surfaces. Also disclosed herein are friction stir welding assemblies for providing the deposition friction stir weld as well as processes for depositing filler material and contouring a workpiece surface.

Abstract: A processing operation control method controls a processing operation in which a rotary tool 1 is rotated by a rotative drive unit 51, and presses the rotating rotary tool 1 is pressed by a pressing unit 52 to force the rotating rotary tool 1 into workpieces W1 and W2. Load placed on the rotary tool 1 during the processing operation is measured, an optimum rotating speed at which the rotary tool 1 is to be rotated and/or an optimum pressure to be applied to the rotary tool 1 for processing the workpieces W1 and W2 is determined on the basis of the measured load placed on the rotary tool 1. The rotative drive unit 51 and/or the pressing unit 52 are controlled on the basis of the optimum rotating speed at which the rotary tool 1 is to be rotated and/or the optimum pressure to be applied to the rotary tool 1.

Abstract: A multi-pass friction stir weld joint and method for forming such joints are provided. The multi-pass weld joint is formed of at least first-pass and second-pass friction stir weld joints that are disposed in the workpiece in a substantially parallel configuration. The first- and second-pass joints define transversely opposite advancing and retreating sides, and the second-pass joint is disposed to at least partially overlap the retreating side of the first-pass joint. Thus, at least some of the material of the workpiece in the first-pass joint is processed during the formation of the second-pass joint.

Abstract: An adapter for use in friction stir welding is configured to be mountable in and rotated by a standard milling machine. In one embodiment, the adapter includes an upper housing, a lower housing, and a mounting element for transmitting rotational movement from the milling machine. At least a portion of the mounting element is mounted in the upper housing. The adapter may also include a tool holder connected to the lower housing and rotated by the mounting element; and a displacement mechanism for providing movement of the tool holder relative to the mounting element. The displacement mechanism may be isolated from the rotational movement of the mounting element and the tool holder. The displacement mechanism of the adapter may also include at least one piston cylinder assembly. In one embodiment, the upper housing and the lower housing form a part of the piston cylinder assembly.

Abstract: An apparatus and method for forming a workpiece to a desired, non-planar configuration are provided. At least one friction stir forming tool, having a shoulder and a pin, is used to urge the workpiece to the desired configuration and friction stir form the workpiece. The forming tool can urge the workpiece against a contour surface of a die or a shoulder that is opposite the structural member from the tool. Thus, the forming tool plasticizes a portion of the workpiece and urges the workpiece to the desired configuration. In addition, the material properties of the workpiece can be improved by the friction stir processing.

Abstract: A process prevents a reduction in the strength of the joint between the liner components, and assures high productivity without impairment. The peripheral walls (6, 7) of the liner component (4) and each of the second liner components (5) are brought into contact with each other, a probe (22) of friction agitation joining tool (20) is placed into the two liner components across the contact portions thereof, and the probe (22) in rotation is thereafter moved relative to the two liner components (4, 5). Assuming that the number of revolutions of the probe (22) is R rpm and that the speed of joining of the two liner components (4, 5) is V mm/min, R/V is in the range of 2?R/V?12.

Abstract: The invention relates to an orbital friction welding method and a friction welding device for welding workpieces by means of friction welding units, wherein the workpieces are pressed against each other in the contact plane during the application of the oscillation energy. To this effect, n>1 friction welding heads are mounted, in a stationary manner, at least on one side of the contact plane in an orbital plane, in the area of the workpieces so that the n>1 friction welding heads, respectively facing one side, are oscillated with the same friction frequency, the same amplitude and the same preset phase position.

Abstract: A joined structure of different metals is usable even in a severely corrosive environments such locations susceptible to salt damage. In a joined structure of different metals, members of different metals are joined to each other in such a manner that a flange is allowed to extend in a direction from the circumferential side of one of the members along the circumference of the other member.

Abstract: A body member and flange members are butted together at first and second abutment portions, and are retained by first and second backing jigs. In this arrangement, inner circumferential surfaces of the first and second abutment portions are fitted on and in close contact with outer circumferential surfaces of the first and second backing jigs. Subsequently, the friction stir welding is performed along each of the first abutment portion and the second abutment portion by using a probe which is rotated at a high speed.

Abstract: In a heat exchanger plate freedom of design of the flow channel is improved. A flat main body on a surface of which is formed at least one first groove having a rectangular cross-sectional shape, and a second groove having a rectangular cross-sectional shape that is narrower than the first groove, and that is formed following along opposite side faces of the first groove at a center of a bottom face of the first groove; and a flat cover which covers an entire surface of the main body, and on a rear face of which is formed a protrusion whose top face contacts a bottom face of the first groove and whose opposite side faces contact opposite side faces of the first groove, when the cover is superposed on the surface of the main body, and which forms a flow channel by means of a top face thereof and the second groove, are joined by friction stir welding.

Abstract: An apparatus and method for joining structural members to form preforms and structural assemblies are provided. The structural members are positioned so that joining surfaces thereof define an angled aperture, such a slot or frustoconical bore, that receives a corresponding joining member. The joining member is urged into the aperture against the joining surfaces and moved, for example, by oscillating or rotating the joining member, to friction weld the joining member to the structural members. Each structural member can include a clamping portion that is received by a clamping device that prevents the aperture from opening as the joining member is urged into the aperture. A gripping portion of the joining member and the clamping portions of the structural members can be trimmed from the resulting preform to form a finished structural assembly.

Abstract: This invention relates to methods for making high strength friction stir welded joints. Broadly the invention provides for a method for making a friction stir welded joint including the steps of applying an adhesive to one surface of a first material to be welded; applying a second material to be welded to the adhesive the first material; curing the adhesive; and forming a friction stir weld joint through the cured adhesive by friction stir welding.

Abstract: A method of repairing an integral engine component is disclosed. The method of repairing the integral engine component may include removing a damaged portion of a first member to create a void. The method of repairing the integral engine component may also include friction welding in place a second member to at least partially fill the void.

Abstract: A method of manufacturing a workpiece is provided. The method generally includes friction stir welding at least one structural member, selectively removing material from the surfaces of the workpiece at the location of a friction stir weld joint, and thereafter subjecting the workpiece to a solution treat, quench, and age treatment. By selectively removing regions from the surfaces of the workpiece that are defined by nonuniform material properties adapted to nucleate nonuniform grain growth during the solution treat, quench, and age treatment, a subsequent grain growth during the thermal treatment can be at least partially prevented.

Abstract: A method of producing a connecting rod with a bearing, in which both a process for producing a bearing separately from a connecting rod and a process for assembling the bearing to the connecting rod can be eliminated to reduce processes, labor, and costs to produce the connecting rod. A hollow cylindrical molding of a bearing metal material is inserted and fitted, as an inner member, inside an inner surface of a circular large end hole of a large end section of a connecting rod. A tapered surface of a rotary pressing tool is pressed, while rotating, to the hollow cylindrical molding to heat and soften the hollow cylindrical molding, causing the hollow cylindrical molding of the bearing metal material to plastically flow axially and radially outward, whereby a bearing metal layer is directly joined and formed on the inner surface of the large end hole.

Abstract: There is provided a friction stir spot joining device in which a pin can be simply and surely caused to come into or out from a tip end of a joining tool by driving a pin extraction motor when the pin extraction motor is used so as to cause the pin to come into or out from the tip end of the joining tool.

Abstract: The present invention is relates to a method for alternately laminating each first metal sheet and each second metal sheet in three or more layers, wherein a melting point of the second metal sheet is higher than that of the first metal sheet, and welding them together by friction stir welding. Furthermore, under a state where those three or more metal sheets are so laminated that an edge of the first metal sheet protrude outward compared to an edge of the second metal sheet, the friction stir welding is executed by pressing a welding tool against only the edge of the first metal sheet.

Abstract: This invention provides a configuration of a joint that allows a satisfactory welded joint to be formed with reduced deformation of the joint region when two-face structures (panels) are friction-welded end to end. The panels 31, 32 each have two substantially parallel plates 33, 34 and a third member 35 connecting the two plates 33, 34. The end portions of the plates 33, 34 of one panel 32 are friction-welded to the end portions of the plates 33, 34 of the other panel 32. At least one of the panels has a plate 36 at its end for connecting the plates 33 and 34 and has a rigidity to support a pressing force produced during the friction welding.

Abstract: A method of friction stir welding and a non-consumable multi-section faced 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 includes a multi-section face, having a first face section and a second face section, 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: This invention provides a configuration of a joint that allows a satisfactory welded joint to be formed with reduced deformation of the joint region when two-face structures (panels) are friction-welded end to end. The panels 31, 32 each have two substantially parallel plates 33, 34 and a third member 35 connecting the two plates 33, 34. The end portions of the plates 33, 34 of one panel 32 are friction-welded to the end portions of the plates 33, 34 of the other panel 32. At least one of the panels has a plate 36 at its end for connecting the plates 33 and 34 and has a rigidity to support a pressing force produced during the friction welding.

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).

Abstract: A preform with edges overlapped and jointed each other and first and second outer members for forming outer surfaces of a hydroformed product, and reinforcement members that are jointed to the first and second outer members to form reinforcement ribs that divide a hollow cross section of the outer surfaces, the reinforcement members having dimensions capable of suppressing elongation in a tensile direction due to a tensile force that develops during hydroforming.

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.