Abstract: A vacuum attachment tool includes a hollow body extending from a first end to a second end and defining a flow path, and a conduit connector disposed at the second end of the hollow body. The conduit connector includes an inner collar having an inner diameter sized to receive a first vacuum conduit having a first diameter, and an outer collar having an inner diameter sized to receive a second vacuum conduit having a second diameter greater than the first diameter. The outer collar is formed separately from the inner collar and is coupled to the inner collar.

Abstract: A method of fusing first and second metal objects together at respective first and second ends thereof, the first and second ends being partially defined by respective first and second end walls thereof. One or more recesses is formed in one or both of the first and second ends. The ends are heated to a hot working temperature in an inert atmosphere, and the first and second end walls are engaged with each other, to form one or more deformed parts of the first and second ends. While the first and second end walls are engaged, one or more objects is rotated around its axis, to squeeze the one or more deformed parts into the one or more recesses respectively. The first and second metal objects are allowed to cool, to fuse the first and second metal objects together at the first and second ends.

Abstract: A machine tool includes a first spindle, a second spindle, and a joining means for joining the axial ends of workpieces gripped by the spindles to form a joined workpiece. The machine tool further includes an electric servomotor for moving the first spindle in the direction intersecting the axis of the first spindle, a current value detection means for detecting the current value of the electric servomotor, and a misalignment detecting means for detecting misalignment of a first workpiece and a second workpiece in the joined workpiece, based on the current value detected by the current value detection means when the joined workpiece gripped by the two spindles is rotated.

Abstract: With an idler, a first member includes a first boss portion, a first rim portion, and a side plate. A second member includes a second boss portion, a second rim portion, and a side plate. A third member includes a third boss portion having a third axle hole portion configured to allow insertion of an axle. The third boss portion is disposed between the first boss portion and the second boss portion. A first welded portion is formed between the second boss portion and the third boss portion and connects the second and third boss portions. A second welded portion is formed between the first boss portion and the third boss portion and connects the first and third boss portions. A third welded portion is formed between the first rim portion and the second rim portion and connects the first and second rim portions.

Abstract: A cam assembly in a linear friction welding system includes two power shafts. Each of the shafts have two timing gears mounted thereupon. For one of the shafts, one of the timing gears includes a slot extending within the timing gear which is formed as an arc about a center of rotation of the power shaft. The other timing gear on that shaft includes a fixed pin which extends into the slot. A cross-over shaft is operably connected to both power shafts.

Abstract: A method for reducing stress and distortion in a component during a friction welding process includes securing first and second workpieces of the component within an inertia welding machine such that the first and second workpieces are affixed in opposition to each other. The method also includes securing at least one annular support member at least partially around the first workpiece and/or the second workpiece at a location having a reduced cross-section as compared to remaining portions of the first workpiece and/or the second workpiece. Further, the method includes rotating the first workpiece to a predetermined rotational speed. In addition, the method includes engaging the second workpiece with the rotating first workpiece so as to generate frictional heat therebetween, thereby welding the first and second workpieces together. As such, the annular support member(s) supports the location having the reduced cross-section during welding.

Abstract: The method includes a step of preparing a first member made of a first metal and a second member made of a second metal having a smaller deformation resistance than the first metal, and a step of joining the first member and the second member. The step of joining includes a step of disposing the second member in a cavity of a mold, a step of heating the first member and the second member by relatively rotating the first member with respect to the second member, while pressing the first member against the second member, without changing a positional relationship, and a step of cooling the first member and the second member with the members being in contact with each other. In the step of disposing, the second member is disposed such that a second member contact surface is surrounded by the sidewall of the cavity.

Abstract: Systems and methods for calculating efficiency of a rotary friction welding process are described herein. An example method can include measuring kinetic energy transferred from a welding machine to an interface of a welded joint, and calculating an efficiency of a rotary friction welding process based on the measured kinetic energy. For example, a workpiece torque experienced by a sample can be measured, and an energy associated with the workpiece torque can be calculated. The efficiency of the rotary friction welding process can then be calculated using the energy associated with the workpiece torque.

Abstract: A method (56) for fabricating an integral assembly (24) is disclosed. The method comprises providing (56) a first workpiece (26) having a first surface (46) and a second workpiece (28) having a second surface (50), performing a first bonding process between the first surface (46) of the first workpiece (26) and the second surface (50) of the second workpiece (28) to form a sub-assembly workpiece (48), and performing a second bonding process between a third surface (52) of the sub-assembly workpiece (48) and a fourth surface (54) of a third workpiece (30) to form the integral assembly (24). The material properties of the first workpiece (26) are different from material properties of the third workpiece (30).

Abstract: An apparatus for forming a friction weld, the apparatus comprising: a support arrangement; a holding member, which is supported by the supporting arrangement, and which may be driven to rotate with respect thereto, or move with respect thereto along an arcuate path; a consumable element having a first joining face, the consumable element being mounted in a mounting location on the holding member so that the first joining face is exposed, wherein the consumable element is rotatable with respect to the holding member about a first centre of rotation, and wherein when the holding member is driven to rotate or move with respect to the support arrangement, the first centre of rotation travels in an orbital motion with respect to the support arrangement; and at least a first alignment arrangement, positioned to hold a first workpiece in place so that an attachment face of the first workpiece is aligned with the first joining face of the consumable element.

Abstract: A pressure welding method and a pressure welding device (1) includes a plasticizing unit (7), a compression unit (8), a machine head (13) that includes a spindle (54) and a component holder (34). The pressure welding device (1) further includes a spindle drive (56) and an actuation mechanism (41) that includes an actuation drive (65) for the component holder (34). The actuation drive (65) is placed between the spindle drive (56) and the spindle (54) within a drive train (57).

Abstract: An arrangement for electrically conductively connecting a cup shaped copper contact part to an electrical conductor that is made of a plurality of individual wires containing aluminum. The arrangement has a cup-shaped contact part, which includes a bottom and a cylindrical sleeve integrally connected to and projecting away from the bottom with tight contact of the sleeve to the conductor. The cup-shaped contact part is configured to be pushed onto the conductor until the end face of the conductor rests against the bottom of the contact part. At least one rotating tool is configured to be removably placed with sustained pressure, subsequently to the cup-shaped contact part, until the material of the conductor is softened due to the increased temperature of the material of the conductor due to friction to such an extent that it integrally connects to the contact part.

Abstract: Pneumatic machining device includes a fixing plate, a hollow piston shell, a piston group, a machining tool, a first sealing group, and a second sealing group. The piston shell is fixed to the fixing plate and coupled to a first external pressure source and second external pressure source to feed gas into the piston shell to drive the piston group and the machining tool, respectively. The piston group and the first and second sealing groups are received inside the piston shell. The piston group is driven by the first external pressure source to move away from the fixing plate. The first and second sealing groups divide the piston shell into a number of chambers for controlling a gas pressure. The machining tool is coupled to the piston group and extends out of the piston shell to machine a workpiece as the piston group moves away from the fixing plate.

Abstract: A method for forming a propshaft assembly includes: providing a tube having an annular wall member and an axial end face; providing a yoke having body and a pair of arms that extend from the body, the body defining an annular groove having sidewalls and an end face, the sidewalls being spaced apart to receive the annular wall member; spinning at least one of the tube and the yoke while engaging the axial end face to the end face of the annular groove to plasticize a portion of the yoke and a portion of the tube; and driving the yoke and the tube together to fuse the plasticized portion of the yoke and the plasticized portion of the tube together and thereby form a friction weld; wherein the tube is fused to the yoke over portions of the yoke that correspond to the sidewalls and the end face.

Abstract: A system can include a controller; a force applicator; a rotatable shaft centering collet; a drive mechanism that rotates the rotatable shaft centering collect; and a laser beam unit.

Abstract: To provide a turbine rotor which enables mass production with a low-cost apparatus and which capable of suppressing leaning of the rotor shaft after welding to improve the yield, while a turbine blade rotor 12 and the rotor shaft 14 are fit to each other with concave and convex portions 12a and 14a and are permitted to be rotated, laser beam L from a laser beam generating device 30 is applied to a joint face 16 along the circumferential direction to weld the welding portion. Then, laser beam L is polarized to temper a region X on the rotor shaft side containing the welding portion with laser beam L. In contrast to residual stress R1 having a local angular distribution generated during the welding, residual stress R2 is permitted to be generated over the entire circumference by tempering. Leaning of the rotor shaft 14 after cooling is thereby be suppressed.

Abstract: A rotary machine includes a machine stator and a machine rotor rotatable relative to the machine stator and having a metal shaft portion, a composite impeller portion, and at least a first metal ring portion securing the composite impeller portion to the metal shaft portion, the metal ring portion having a first interface with the composite impeller portion and a second interface with the metal shaft portion.

Abstract: A friction-welded ground assembly that includes an alloy substrate with a clearance hole; an aluminum alloy weld nut having a bolt bore and an outer wall; and a grounding bolt. The bore is located substantially within the clearance hole and a portion of the outer wall is joined to the substrate at a friction-welded attachment. Further, the bolt is threaded within the bore. In addition, a method for making a ground includes the steps: rotating an aluminum alloy weld nut having an outer wall at a predetermined speed; lowering the outer wall of the rotating nut into contact with an aluminum alloy substrate to generate a frictional force for a friction time; arresting the rotation of the nut; and applying an axial forging force to the outer wall and the substrate for a forging time.

Abstract: A method of inertia friction welding a superalloy substrate, the method including: rotating and forcing a deposit material (110) against the superalloy substrate (100); plastically deforming at least one of the deposit material (110) and the superalloy substrate (100) to form a weld joining the deposit material (110) to the superalloy substrate (100), thereby forming an assembly; and heat-treating the assembly. Heat-treating includes: a post-weld intermediate stress-relief (ISR) treatment; a solutionizing treatment; and a precipitation hardening heat treatment.

Abstract: A method for friction stir welding is provided. The method may include determining the temperature of one or both parts being welded. The parts may then be heated to a desired temperature and then friction stir welded together. By preheating the parts, the friction required to plasticize the parts during welding may be reduced. Thereby, the rotational speed of the friction stir welding tool may be reduced, and thus the tool life may be extended without decreasing the rate at which welds are created. Additionally, the cooling rate of the weld may be regulated with a thermal control device.

Abstract: A welding tool for friction welding a workpiece, the tool including: a probe having a core including a ceramic material, the probe having a surface coating including a metallic material covering at least part of a contact zone of the probe.

Abstract: Tubulars are joined to each other without rotation of the tubulars. A coupling is placed between the aligned tubulars and is supported for rotation or oscillating about its longitudinal axis. The tubulars are clamped in a manner that allows a compressive force to be transmitted to the coupling as the coupling is rotated. An induction device can preheat each connection site before friction welding and/or provide heat as the connection is made and is allowed to cool down. The process can continuously create a string of casing or liner that can be run in or drilled into a wellbore.

Abstract: A method for the friction stir welding of two components, in particular of two shell components of a fuselage structure of an aircraft and spacecraft, said method comprising the following method steps: positioning the two components relative to one another in such a way that a connection region is formed between the two components; friction stir welding the two components by means of a friction stir welding tool which penetrates the connection region in order to produce a weld which permeates the connection region with the formation of an unpenetrated weld edge portion of the connection region; and introducing internal compressive stresses, at least in the weld edge portion of the connection region. Further a device for the friction stir welding of two components, in particular of two shell components of a fuselage structure of an aircraft and spacecraft is provided.

Abstract: A method for joining materials such as metal alloys that includes a first component, wherein the first component includes a first alloy having a known austenization temperature below which martensite forms when the component is heated and then cooled at a predetermined rate of cooling; a second component, wherein the second component includes a second alloy; and a welding apparatus operative to create a weld between the first and second components without crossing the austenization temperature of the first alloy.

Abstract: A burring apparatus for a friction welding machine comprises a clamp unit provided at the front end of a horizontal main spindle, for holding work piece W1 coaxial with the main spindle, a clamp unit provided at the front end of a slide movable to and away from the main spindle in the direction of the axis of the main spindle and a doughnut-shaped cutter for shearing off a burr. Work piece W2 is moved forward together with the slide until work piece W2 comes into contact with work piece W1 so that the mated ends of work pieces W1 and W2 are friction welded together to form a joint work piece W. The burr formed on the jointed work piece W is sheared off by the cutter. The jointed work piece W is then liberated from the main spindle.

Abstract: A system and method for modifying a work piece surface of high melting temperature materials such as Advanced High Strength Steels, wherein a friction stir welding tool may include cutting elements located on the outside diameter of a collar assembly, wherein the collar assembly may be retrofitted for existing friction stir welding tools, or may be designed as a custom attachment for a new hybrid friction stir welding tool, wherein the surface of the work piece may be modified by removing detrimental flash and burr created during operation of the friction stir welding tool.

Abstract: In a friction stir welding apparatus, workpiece fixing surface plates (3a, 3b) are installed on a framework (1). In addition, a welding apparatus main body (8) including a bobbin tool (5) having a probe (5a) protruding upward from a gap (4), a spindle (6) configured to attach the bobbin tool (5) to an upper end section thereof, and a spindle driving apparatus (7) configured to pivot the spindle (6) is movably installed at the framework (1) in a longitudinal direction of the gap (4) via linear guide mechanisms (9) installed at both sides of the welding apparatus main body (8). Further, a moving apparatus (10) is installed to move the welding apparatus main body (8) in the longitudinal direction of the gap (4). According to the friction stir welding apparatus, since the welding apparatus main body (8) is supported by the framework (1) via both of the linear guide mechanisms (9), a large welding reaction force can be sufficiently received.

Abstract: A downhole tool and method for manufacturing such downhole tool. The downhole tool includes a bit body having a blank and a matrix bonded to and surrounding the blank, a shank having a threaded connection at one end, and a butt joint formed within a gap formed between the blank and the shank and coupling the blank to the shank. The blank includes a first planar surface while the shank includes a second planar surface opposite the one end. The butt joint is formed between the first and second planar surfaces when positioned adjacent to one another, wherein the first planar surface is positioned external to the matrix.

Abstract: A friction stir welding includes a main body for holding a tool and a hot air and cool air separating unit. The separating unit is disposed at the main body and separates a supplied gas into hot air hotter than the gas and cool air cooler than the gas in a tube portion and ejects the cool air from a first end of the tube portion and ejects hot air from a second end of the tube portion. The hot air is supplied to a front side of a movement direction of the tool in the surface of the work piece from a tool side of the friction stir welding apparatus and the cool air is supplied to a rear side of the movement direction of the tool in the surface of the work piece from the tool side of the friction stir welding apparatus.

Abstract: A hole in a metal workpiece is filled by friction plug welding. The weld between the workpiece and the plug is reinforced by a weld land in the workpiece that surrounds one end of the plug. The weld land is formed by extruding a portion of the plug into a cavity in an anvil used in the welding process.

Abstract: A method for controlling friction stir welding is provided. The method may include initiating friction stir welding and determining the position of a friction stir welding tool and at least one part being welded. The method may also include adjusting the position of the friction stir welding tool while friction stir welding based at least in part on the positions of the tool and at least one of the parts. The position of the parts may be determined downstream of the friction stir welding tool in order to prospectively account for the position of the parts. Accordingly, the position of the friction stir welding tool may be dynamically adjusted during friction stir welding to account for part movement. Related systems and computer code are provided.

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 manufacturing turbine engine casings having at least one boss includes, in one exemplary embodiment, forming an engine casing having an outer wall, machining a tapered opening through the casing outer wall, and machining a tapered portion in a metal plug where the tapered portion is sized to mate with the tapered opening in the casing outer wall. The method also includes inserting the metal plug into the tapered opening in the casing outer wall, and welding the metal plug to the casing.

Abstract: A friction stir welding method in which a welding tool rotating around an axis is pressed against a welding target portion of workpieces supported by a backing member so that frictional heat is generated and the friction heat softens the welding target portion. The welding tool is at least partially inserted into the softened welding target portion and stirs the softened welding target portion so that the welding target portion is stir welded in a solid phase state. The friction stir welding method includes detecting a temperature of a temperature measurement point provided in the backing member, and calculating an estimated temperature of the welding tool from the detected temperature of the temperature measurement point, based on a predefined correlation between a temperature of the welding tool and a temperature of the backing member.

Abstract: A process of fabricating a rotating component and a rotating component formed thereby. The rotating component has a rotational axis, at least one rim member, at least one disk member, and at least one airfoil member. The rim and disk members are welded together to define a first solid-state weld joint lying in a first plane that is not parallel to the rotational axis of the rotating component. The airfoil member is welded to the rim member to define a second solid-state weld joint lying in a second plane that is not parallel to the rotational axis of the rotating component. The rim member is located in a radially outward direction from the disk member, and the airfoil member is located in a radially outward direction from the rim member.

Abstract: The current invention provides a drill pipe of standard weight with an integral wear pad. The drill pipe with integral wear pad provides increased durability while retaining the strength, flexibility, lightweight, and other performance characteristics of standard weight drill pipe. The current invention also provides methods for making a standard weight drill pipe with integral wear pad.

Abstract: A hole in a metal workpiece is filled by friction plug welding. The weld between the workpiece and the plug is reinforced by a weld land in the workpiece that surrounds one end of the plug. The weld land is formed by extruding a portion of the plug into a cavity in an anvil used in the welding process.

Abstract: A friction stir welding apparatus includes: a thermocouple and a temperature measurement device which are configured to detect a temperature of the temperature measurement point; a temperature monitor configured to calculate an estimated temperature of the welding tool from the detected temperature of the temperature measurement point, based on a predefined correlation between a temperature of the welding tool and a temperature of the backing member; and a controller configured to perform a predetermined procedure based on the estimated temperature of the welding tool so as to prevent overheating of the welding tool.

Abstract: The present invention relates to a method for manufacturing a printed circuit board, which includes: preparing a base substrate with an electrode pad; providing a conductive material having a predetermined height; disposing the conductive material on the electrode pad; and forming a conductive post on the electrode pad by bonding the electrode pad and the conductive material, and can achieve a fine pitch and easily implement a conductive post with a high aspect ratio.

Abstract: A friction stir welding tool and process for lap welding dissimilar materials are detailed. The invention includes a cutter scribe that penetrates and extrudes a first material of a lap weld stack to a preselected depth and further cuts a second material to provide a beneficial geometry defined by a plurality of mechanically interlocking features. The tool backfills the interlocking features generating a lap weld across the length of the interface between the dissimilar materials that enhances the shear strength of the lap weld.

Abstract: A method of performing ultrasonic stir welding uses a welding head assembly to include a plate and a rod passing through the plate. The rod is rotatable about a longitudinal axis thereof. In the method, the rod is rotated about its longitudinal axis during a welding operation. During the welding operation, a series of on-off ultrasonic pulses are applied to the rod such that they propagate parallel to the rod's longitudinal axis. At least a pulse rate associated with the on-off ultrasonic pulses is controlled.

Abstract: An ultrasonic stir welding system includes a welding head assembly having a plate and a rod passing through the plate. The rod is rotatable about a longitudinal axis thereof. During a welding operation, ultrasonic pulses are applied to the rod as it rotates about its longitudinal axis. The ultrasonic pulses are applied in such a way that they propagate parallel to the longitudinal axis of the rod.

Abstract: A method of producing a welded assembly from a first metal part and a second metal part includes bringing the first metal part and the second metal part into contact with one another at a joint region while providing a flash ring separator adjacent the joint region configured to intercept and separate flash. After heating the joint region, the first and second metal parts are forced together to join the first metal part to the second metal part, extruding metal flash from the joint region. The extruded flash impinges on the flash ring separator, forming a flash ring having at least one indentation. During subsequent machining of the welded assembly to remove the flash ring, the flash ring may fragment at the indentation, so that it does not cause damage by becoming hung around the assembly.

Abstract: A joining method of a pair of workpieces, each workpiece having a non-flat portion and an abutting surface continuous to the non-flat portion, wherein the method provides an extension portion on each of the workpieces, the extension portion having a surface continuous with the non-flat portion and the abutting surface and projecting outward from the workpiece, and holding the workpieces so as to form a joining line between the non-flat portions of the respective workpieces by bringing the abutting surfaces thereof into contact with each other. Also disclosed is a joining tool having a substantially cylindrical shoulder portion and a projection projecting outward from a tip surface of the shoulder portion.

Abstract: A method of manufacturing a fuel injector having high-flow orifices in its tip includes removing a bulb from a fuel injector tip having at least one spray orifice with a first diameter, and friction welding a slug to the fuel injector tip, including forming a fused interface of material of the slug and material of the fuel injector tip. The method further includes modifying the slug subsequent to friction welding the slug to the fuel injector tip, including forming a new bulb from the slug having at least one spray orifice therein with a different diameter than that of the removed bulb. A remanufactured fuel injector, and fuel injector tip, includes an injector tip body having a first tip portion of a first material and a second tip portion of a material compatible for friction welding with the first material.

Abstract: A solid state method for the preparation of composite materials incorporating metal and nano materials is provided, wherein nano materials are deposited on a substrate and incorporated into the substrate structure by friction stir welding. Also provided are composite materials that include nano materials, which are prepared by friction stir welding.

Abstract: The present invention is a fusion-bonded product having a high-strength part, comprising: a first preform (2a) constituted by integrally, frictionally pressure-welding a first low-carbon steel part (L1) made of low-carbon steel containing less than 0.45% of C and a high-carbon steel part (H) made of high-carbon steel containing not less than 0.45% of C; and a second preform (2b) having a second low-carbon steel part (L2) made of second low-carbon steel containing less than 0.45% of C; wherein the high-carbon steel part (H) of the first preform (2a) is provided with a high-strength part (9) that has been previously formed into a desired shape and quenched, the second low-carbon steel part (L2) of the second preform (2b) has been previously formed into a predetermined shape, and the first low-carbon steel part (L1) of the first preform (2a) and the second low-carbon steel part (L2) of the second preform (2b) are bonded to each other by fusion welding.

Abstract: In a friction stir welding method, a tool is moved being rotated along portions to be joined of a work piece, where the portions include a corner with a smaller curvature that connect two portions with larger curvatures. The method includes the steps of setting the work piece on a supporting member, rotating the tool around a center axis thereof, moving the tool toward the work piece to penetrate a portion of the tool into the work piece at the portions to be joined, and moving and turning the tool along the portions to be joined. A rotation speed of the tool around the center axis thereof is decreased to be smaller at the corner with the smaller curvature than the rotation speed of the tool around the center axis thereof at the portions with the larger curvatures.

Abstract: A structure includes a nanophase titanium node and a plurality of nanophase aluminum struts. Each of the plurality of nanophase aluminum struts is bonded to the nanophase titanium node at a weld joint.

Abstract: In a friction stir welding apparatus for overlapped joints provided with a rotor having a shoulder and a probe that is provided so as to protrude from the shoulder of the rotor and also so as to be disposed concentrically with the center axis of the rotor, a helical groove is formed in the peripheral surface of the probe, from the tip of the probe toward the shoulder, and the depth of the groove is formed so as to gradually decrease from the tip of the probe toward the shoulder.