Abstract: First and second superalloy workpieces are inertia welded together by rotating the first workpiece to an initial contact speed greater than about 750 surface feet per minute, and frictionally engaging under a weld load the first and second workpieces to effect an inertia weld therebetween.

Abstract: A method of joining a magnetic armature of an electromagnetic actuator to a shaft is provided. The method includes holding the armature stationary while spinning the shaft. The spinning shaft is then pressing against the stationary armature such that friction between the shaft and the armature causes a portion of the armature and a portion of the shaft to melt and define a weld joint. The weld joint is permitted to cool thereby joining the shaft to the armature.

Abstract: A new method for forming a joint between a molybdenum-based alloy structure and a structure formed from a more ductile alloy is disclosed. The method involves the solid-state bonding of the two structures, which can be carried out by a variety of techniques, such as inertia-welding or explosive-welding. The molybdenum-based alloy may be a TZM-type material, while the more ductile alloy may be tantalum-based, niobium-based, or nickel-based, for example. This method is especially useful in the manufacture of x-ray devices, such as those which include rotary anode assemblies. As one illustration, the method can be used to provide a very strong joint between a target formed from a molybdenum alloy and an insert formed from a tantalum alloy. Related x-ray assemblies are also described.

Abstract: Hollow ball bearings of improved strength and uniformity are produced by causing identical first and second hemispheric units to rotate at different speeds in facing relationship upon a common axis, and forcing the hemispheres into aligned contact. The frictional heat generated by such contact melts the material adjacent the open rim of each contacting hemisphere. The molten material is distributed by centrifugal force about the interior of the hemispheres. The speeds of the two hemispheres are then equalized with attendant cooling and re-solidification of the molten material, thereby producing a hollow sphere.

Abstract: The invention is directed to a method and a product produced by the method where in there is created a multi-metal composite object that takes on the configuration of a shaft which would include in combination an outer annular element having an outer cylindrical surface and an inner frusto conical annular metal element of a dissimilar metal. The inner frusto conical annular metal element of dissimilar metal includes an inner mating frusto conical surface bonded to a mating outer frusto conical surface of another metal element to thereby provide a multi-metal element composite shaft. The composite object in a preferred embodiment of the invention takes the form of a multi-metal element composite gear, web and shaft that includes a steel outer annular gear toothed element, an inner aluminum element and a titanium element that provides a gear web and shaft.

Abstract: A tube coupling comprising a metal tube of relatively uniform thickness and having a radially outwardly expanded integral sleeve at one end thereof, and a radially extending tube shoulder being defined at the juncture at which the sleeve is expanded outwardly, the tube having a throughbore of a first inner diameter, and the expanded sleeve having a throughbore of a second inner diameter greater than the first inner diameter and concentric therewith. A cylindrical, hollow insert is located concentric with the axis of the tube, the insert including a radially extending annular collar at one end thereof. The collar has a tube end face abutting the radial tube shoulder and inertially welded to the tube at the interface of the tube end face and the radial tube shoulder. The insert includes at its other end a cylindrical barrel portion having hose locking and sealing means.

Abstract: A process is described for inertia bonding a hollow shaft made of superalloy materials without causing compressive deformation in the shaft due to the high compressive forces generated in the segmented collet which grips the shaft. A method is also described for minimizing the residual stress in an inertia bonded joint, where the wall thicknesses of the two shaft portions to be bonded are unequal, by independently controlling the gripping forces on the portions so as to provide equal diameter reduction during the bonding process. A method for converting a front loading inertia bonding machine to a rear loading bonding machine is also described.

Abstract: An automated heat pipe processing system is able to take a heat pipe casing and an end cap for the heat pipe casing and form these into a heat pipe within a totally contained system. The heat pipe casing and end cap are cleaned by means of glow-discharge plasma, a bakeout heating, if required. After cleaning, a working fluid is placed within the cleaned heat pipe after which the end cap is fixedly attached to the heat pipe casing by means of inertia welding. This in-situ fabrication of the heat pipe minimizes defective end products and steps to fabricate such.

Abstract: A hybrid package in which Kovar feedthroughs are friction welded to an aluminum housing. Friction welding produces a very strong weld joint which resists the thermal stresses induced between the aluminum housing and Kovar feedthroughs by the large difference in their coefficients of thermal expansion. Friction welding also produces a very small heat affected zone, while brazing, soldering and other types of welding produce large heat affected zones which can cause annealing problems. The aluminum package is easy to machine, light in weight and provides good heat dissipation for the hybrid microcircuits in the package.

Abstract: A method for inertia welding axially symmetric articles while controlling the gripping force applied to the rotating component is described. A spacer inserted into the rotating headstock creates an alternative path for the axial force in excess of that required for causing gripping of the rotating component, and thus minimizes distortion of the inertia welded article. This is particularly useful in welding high strength superalloy articles, where extremely high axial forces are required to produce an adequate weld joint.

Abstract: A method is disclosed for controlling the magnitude and location of the weld notch which results from inertia welding of certain materials, such as superalloys. By controlling the size and geometry of the articles being joined a curved weld zone will result and the material expelled from the weld zone which produces the weld notch will be directed in a fashion which moves the weld notch outside of the original diameter of the articles being joined. The resultant welded article consisting of a larger portion and a smaller portion can be machined to the size of the smaller portion without any residual weld notch.

Abstract: Geometries are described for joining superalloy articles by inertia welding. First and second hollow superalloy articles are joined wherein the first article has an inside and an outside diameter which are less than the inside and outside diameter of the second article. This produces a staggered joint geometry which results in curved "S" shaped weld zone and beneficial control of the residual weld notch.

Abstract: A composite compressor wheel for turbochargers and the like comprises a cast shell having aerodynamically contoured centrifugal impeller blades and a hub section defining a generally conical recess into which a hub insert of noncast material resistant to stress failure is secured as by inertia welding. In use of the composite wheel, the hub insert substantially occupies high stress regions within the wheel to improve wheel fatigue life.

Abstract: A cathode ray display tube has a mild steel envelope part (10) with a tubular copper pump stem (20) sealingly attached thereto by friction welding. A method of attaching the pump stem involves forming the pump stem initially with a closed end, rotating the pump stem relative to and against the mild steel envelope part and applying pressure to cause friction welding of the pump stem, and thereafter extending the pump stem's bore through its closed end by drilling. A hole may simultaneously be drilled through the envelope part. The friction weld provides reliable vacuum-tightness and strength, and the attachment of the pump stem in this manner can be accomplished using automation quickly and inexpensively.

Abstract: A method of joining impact or cutting heads to the shanks of down-the-hole rock drilling bits utilizing inertia welding techniques wherein the interfacing portions of the heads and shanks are structured to provide appropriate flash relief areas adjacent generally planar and abutting contact surfaces of the heads and shanks so as to promote the thorough and continuous diffusion bonding of the components across the total area of such contact surfaces.

Abstract: A method and apparatus for friction welding a pair of workpieces (45,46) is described. The apparatus comprises a drive assembly (30) for causing relative motion between the workpieces while urging the workpieces together. A load control assembly (20) is provided which is responsive, at least towards the end of a weld cycle, to the rate of motion of one workpiece relative to the other to cause the workpieces to be urged together under a force which increases as the rate of relative motion decreases.

Abstract: Known methods of controlling inertia welding and friction welding processes fail to control metal upset, and so require post machining of the welded components. The invention pre-determines the ideal rates of relative rotation, force applied and metal upset rates for a given material to be welded, enters those rates in a microprocessor memory and then connects the microprocessor to the apparatus on which the weld is to be effected. The microprocessor monitors the actual rates, compares them with the ideal rates and, should differences occur, generates signals from those differences with which to adjust operation of the apparatus.

Abstract: A method of friction welding comprising causing relative rotation between a pair of workpieces by actuating first and second drive means, the first drive means being coupled to a primary source of energy, and the second drive means being adapted to store auxiliary energy; bringing the workpieces into contact with one another under pressure, whereby the first and second drive means are adapted together to supply sufficient rotational energy to overcome the effects of resistive torque between the workpieces on initial contact between the workpieces; and thereafter continuing actuation of the first drive means to maintain relative rotation between the workpieces.

Abstract: An aluminum torpedo piston is provided with a piston head fabricated from a etal matrix composite material composed of aluminum and silicon carbide fibers that are integrally joined by an inertial welding technique. A 23% weight of silicon carbide fibers to powdered aluminum was selected. Resistance to intense heating which would otherwise cause melting and erosion of the piston is avoided to permit longer, high speed runs.

Abstract: Friction welding apparatus comprises a housing (1, 2) and a workpiece support (20', 24) rotatably and axially movably mounted in the housing. An air driven motor (20) is coupled to the workpiece support (20', 24) to cause the workpiece support to rotate relatively to the housing. A compression spring (33) urges the workpiece support in a first axial direction relatively to the housing while a piston (7) responsive to air pressure is provided to move the workpiece support (20', 24) relatively to the housing (1, 2) in a second axial direction opposite to the first direction. Air under pressure is communicated through a common inlet (6) in the housing (1, 2) to a valve arrangement (8, 9, 13, 14) so that air is conveyed along a first path to the drive motor (20) and along a second path to the piston (7). The valve arrangement is such that axial movement of the piston (7) relatively to the housing (1, 2) causes the valve gradually to close thereby gradually stopping rotation of the motor (20).

Abstract: A flywheel starter gear construction which includes a strip of gear stock surrounding a flywheel disc and friction welded to the disc in an annular weld area, the gear teeth on the gear stock being formed by moving the assembly through a pot broach, and the method of forming the flywheel starter gear by selecting a measured length of gear stock, forming it into a circle and friction welding the circular gear stock to the periphery of a flywheel disc, then moving the welded parts through a pot broach to form the gear teeth to serve as a starter gear.

Abstract: An axle assembly includes an axle member, a flange, and a spindle. The flange is provided with a central bore. An end portion of the spindle extends through the central bore of the flange to contact an end of the axle member. A central portion of the spindle contacts a surface of the flange. Separate weld joints are formed between the axle assembly components at the two contact areas. The welding flash around the outer circumference of the weld may be removed to allow for visual inspection. A preferred method of manufacturing the assembly is by a friction or inertia welding process.

Abstract: A thermoplastic fastener having a slight taper, is friction welded to a thermoplastic workpiece. A system for friction welding the fastener includes a way of automatically stopping rotation of the fastener while contact pressure between the fastener and the workpiece is maintained.

Abstract: A method for solid phase welding gold to electrical contact terminals is disclosed. The contact zones of the terminals are moved past and held against a rotating cylinder that has gold electrolytically deposited thereon. The gold is transferred from the cylinder to the contact zones of the terminals by friction welding. The deposited gold is also described.

Abstract: The present invention relates to a method of friction or inertia welding first and second metal components wherein one of the components is provided with an interface surface having a generally convex configuration, and the central portion of the convex-shaped surface is provided with an axially extending raised button. The convex-shaped surface and the raised button are simultaneously formed during a forging operation. The raised button ensures that, during the friction welding operation, the initial contact and friction heat build up will occur at the center of the interface surfaces.

Abstract: A portable apparatus for friction joining metal pieces to an electrical conductor while the conductor is carrying electrical current. The apparatus comprises a spindle adapted to receive and to hold a metal piece in a forward end thereof for rotation against the conductor, and structure is provided for translating the spindle toward and away from the conductor. An air operated motor and flywheel are provided for rotating the spindle, and structure is provided for supporting the apparatus on the conductor.

Abstract: A method and apparatus for making a formed end metal product uses a welding apparatus to perform a forging operation on the end of an elongate metal member. The metal member is located in a workholder of a welding apparatus of the type having a second opposing workholder and a mechanism, such as a hydraulic cylinder, for developing a compressive force between the workholders. The end of the elongate member is upset forged by a die mounted in one, or both, of the workholders. Following the forging operation, a formed end is located in the second workholder and welded to the end of the elongate member. A heating step can be used if hot forging is required. Preferred types of welding apparatus include friction welders, inertial welders, and flash butt welders.

Abstract: A one-piece cylindrical drum of a drum rotor has a plurality of enlarged, axially spaced-apart, annular rim portions through which axial blade root slots are machined. The slots are curved along their length about an axis located radially outwardly of the rim. The rotor is preferably made from a plurality of bonded together cylinder-like sections. After bonding the sections together the curved blade root slots are machined using a circular broach.

Abstract: A method of making brake rods comprising the steps of welding brake rod jaws to the ends of a solid bar or annular member, securing one end of the brake rod against movement, heating the brake rod and aligning the brake rod jaws on the ends of the brake rod so that the lugs of the brake rod jaws are generally parallel to the lug of a jaw on the other end of the brake rod. Alternately, the brake rod may be heated then have one end secured against movement and the lugs of the brake rod jaws aligned.

Abstract: A sucker rod is composed of three initially separate parts comprising a relatively long body member and duplicate relatively short pin members. Upsetting steps are performed on the relatively long body member, whereas only machining steps are employed in making the pin members. One end of each pin member is inertia welded to each end of the body member after the various ends have been cut or ground to provide relatively smooth surfaces.

Abstract: A method of, and apparatus for, friction welding two components such as universal joint members to the ends of a shaft, wherein the shaft is held stationary while the components are rotated against its ends to produce welding conditions, and then released as welding pressure is applied while the components are braked. Allowing the shaft to rotate with the end component during formation of the welds avoids weld quality problems occurring due to the formation and tearing apart of a succession of welds during the time which would be taken for the end components to come to rest if the shaft were held stationary.

Abstract: The invention discloses an apparatus for the radial inertia welding of a al band to the outer surface of a cylindrical metallic structure. The metals may be similar or dissimilar. The band is placed on the inside of a spinning collet and as the cylindrical structure is advanced thru the band, at a predetermined position, it activates the collet jaws, causing the band to be radially compressed onto the cylindrical structure. Friction between the rotating band and the cylindrical structure held by a tailstock creates heat and under the resulting collet jaw pressure welding action results.

Abstract: A hydraulic cylinder assembly including an outer barrel having one or more internal sleeves and a center rod telescopically mounted therein. The outer barrel and internal sleeves each have a bottom end tube welded to one end thereof and a packing gland tube welded to the other end thereof. The center rod has a bottom end tube welded to one end thereof. The bottom end tubes on said barrel and sleeves have end caps removably mounted therein. Stop shoulders are formed integrally with the end tubes of the internal sleeves and center rod. Mating stop shoulders are formed integrally with the packing gland tubes of the outer barrel and internal sleeves. Said stop shoulders are adapted to move into engagement with each other when the hydraulic cylinder assembly is energized.

Abstract: A friction welding apparatus for welding a pair of members in which the welding surfaces of the members are contacted under pressure with each other, relative circular orbit motion of the members producing friction therebetween thereby heating and melting the welding surfaces and the relative circular orbit motion being stopped to locate the welding surfaces in a predetermined position.

Abstract: A method and apparatus for welding a first workpiece which is to be joined to a second workpiece, with said first workpiece extending within or through the second workpiece. The apparatus includes a rotatable workpiece drive member, a workpiece holding fixture for securing at least one other workpiece in position relative to the first workpiece and a radial support for the first workpiece that is separate and spaced from the drive member. Among the preferred embodiments disclosed for providing the radial support are a tailstock supporting sleeve arrangement, collet chucking, and roller type steady rests.

Abstract: A two step inertia welding process is employed to join the stem to the substrate of a disc thereby forming an anode assembly for a rotating X-ray anode tube. The abutting surfaces to be joined are rubbed together to heat the substrate to an elevated temperature, at which time the weld joint is formed by inertia welding.

Abstract: An inertia welding process is employed to join the stem to the substrate of a disc thereby forming an anode assembly for a rotating x-ray anode tube.

Abstract: A valve seat may be formed deep within a valve body by attaching a wear-resistant material to a base material, such as by welding. Similarly, a drive member may be attached to either of the wear-resistant material or the base material. The thus-assembled structure can be rotated at high speeds adjacent a welding seat located deep within the valve body to create a friction or inertia weldment between the seat and base material. Subsequently, the drive material, weldment flash, etc., can be machined away and the wear-resistant material can be machined, if necessary, to create a valve seat of predetermined configuration.

Abstract: A method and apparatus for maintaining quality control in a friction welding operation where two workpieces are relatively rotated while being constantly pressed into engagement at a common interface. One or more operating conditions, including axial upset at the common interface, are monitored and a signal is substantially instantaneously produced to indicate correlation between the monitored operating conditions and respective ranges for those conditions which are predetermined as being representative of an effective bond between the workpieces. In a first embodiment, operating conditions of axial upset, pressure of engagement between the workpieces and relative rotating speed are simultaneously monitored. In a second embodiment, axial upset is monitored in selectively delayed relation to commencement of the weld in order to provide improved quality control over inertia welding.

Abstract: Friction welding apparatus for substantially automatically welding relatively small diameter workpieces.The apparatus comprises a pair of spaced segmented transfer wheels on a single shaft for retaining workpieces and rotating the same between loading, welding and ejection stations, and a plurality of high-speed motors which carry workpieces at the opposite ends of each rotor, such motors being moveable from a load station through a series of speed-increasing stations to a weld station between the several transfer wheels. Hydraulic means then forces the oppositely disposed transfer wheel segments in their weld stations toward the motor therebetween to simultaneously complete two friction welds. Thereafter, the parts are ejected when the wheel segments move to the ejection stations.

Abstract: A friction welding machine having a unitized headstock and tailstock assembly is disclosed. The unitized assembly includes a rigid tailstock housing in which a headstock flywheel is rotatably and slidably disposed. The unitized assembly prevents radial movement of the headstock and tailstock with respect to one another and thereby maintains predetermined workpiece alignment throughout the welding process.

Abstract: A device for controlling the rotational speed of a friction welder as a function of the combined length of the pair of parts to be welded, within predetermined tolerances, so as to produce welded pieces of uniform length in spite of minor variations in the lengths of the parts. Logic and sequencing circuitry specially adapted to carry out this function at minimum cost is also described.

Abstract: Spin welding head is rotated at a predetermined rate by a shaft through a clutch biased into engagement by springs carried by a clutch member which surrounds the shaft. After the rotating head is engaged against the workpiece, the shaft is advanced axially into the head at a predetermined rate through a predetermined distance whereupon shoulders on the head and clutch member interengage to halt the spring induced axial movement of the clutch member with the shaft. Axial movement of the shaft is continued to disengage the clutch and free the head for continued rotation independently of the shaft through its rotational inertia. The mass of the head and its rate of rotation are coordinated to keep the head spinning for long enough to complete the spin welding which was initiated while the head was being driven by the shaft. The shaft also forms a plunger which in each cycle of operation injects lubricant from a reservoir into a passageway system for lubricating the moving parts in the head.

Abstract: A method of producing ball joints of the type that include a ball and stem member pivotally mounted in a housing, the method comprising forming separate stem portions and ball portions and joining the portions at welded junctions to provide pivot members of composite construction. Such pivot members are characterized by relatively large ball diameters as compared to the shank diameters so as to provide a high degree of angularity of movement.

Abstract: A process for bonding a copper or nickel end junction piece to an aluminum electrical conductor wire. The copper or nickel end junction piece is used to make the electrical connection with terminals in meters, fuse boxes, switches and the like, thus eliminating such junctions with the aluminum wire and hence eliminating the possibility of the formation an aluminum oxide connection which may give rise to overheating and subsequent fire. The end junction pieces may be applied on-site after the aluminum wire is cut to the desired length. No special pretreatment of the aluminum wire end is necessary prior to the addition on the end junction piece.

Abstract: Disc brake backing plate with a cup-shaped housing having in one embodiment a weight sandwiched between two resilient plugs and in a second embodiment, a plurality of scrap punch metal particles mixed with and incorporated in a resilient carrier.

Abstract: .Iadd.Method and apparatus for spin-welding thermoplastic articles in which two axially mating sections are driven in rotation relative to each other and then axially abutted in mating relationship. One of the two mating sections is chucked to an inertia member which is brought up to speed by a rotary drive. The rotary drive is uncoupled as the sections are moved into axial abuttment and the braking of the inertia member by the axial abuttment of the sections is transformed into frictional heat which welds the sections to each other. Apparatus for spin welding sections on a production line basis is disclosed. .Iaddend.