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: A system and method for holding a friction stir processing material in place on a substrate having a curved surface for the purpose of mixing the friction stir processing material into the curved substrate using a solid-state process, wherein the system includes selecting one of a variety of mechanical means of attaching the friction stir processing material to the substrate that will enable friction stir processing to be performed that is economical, efficient and safe.

Abstract: A process for connecting two aircraft fuselage segments and a reinforcing profile arranged in the joint region of the two aircraft fuselage segments by friction twist welding using a rotating tool, wherein a cover plate is brought onto the aircraft fuselage segments to be connected above the joint regions and after the friction twist welding the remainder of the cover plate is milled off. This makes it possible to overcome significantly greater gap tolerances in the edges to be connected so that the dimension tolerance requirements for the aircraft fuselage segments can be reduced. Furthermore, a smooth surface can be achieved in the welding region.

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 is taught for creating a hollow sphere that is created by joining two cylinders together that have a semispherical hollow formed in the ends being joined together, wherein a metallic reinforcing disk is inserted at an interface between the two ends of the cylinders, wherein the two cylinders and reinforcing disk are joined using friction stir welding to create an inner sphere from the two hemispherical hollows that is bisected by the metallic reinforcing disk, and wherein the joined cylinders and reinforcing disk are machined to thereby create an outer spherical surface that is centered around the inner sphere.

Abstract: A method of manufacturing a shaft of a surgical instrument including forming a proximal segment of the shaft to include one or more features for operably engaging the shaft to a first component of the surgical instrument, forming a distal segment of the shaft to include one or more features for operably engaging the shaft to a second component of the surgical instrument and forming an intermediate segment of the shaft. The proximal segment is welded to a proximal end of the intermediate segment; and the distal segment is welded to a distal end of the intermediate segment. The proximal and distal segments are welded to the intermediate segment such that the one or more features thereof are aligned in a pre-determined orientation relative to one another.

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: 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 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: 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 friction agitation welding process for the joining of abutting plate-shaped workpieces consisting of an aluminium alloy, wherein a rotating Bobbin tool is moved along a weld between the two plate-shaped workpieces during feed, exerting a first and a second contact pressing force on first and second sides, respectively, and wherein said Bobbin tool is subjected to an additional axial force during its movement along the weld to plastically deform the area of the created welding seam such that the welding seam is pressed towards one side of the plate-shaped workpieces while forming a welding seam elevation protruding opposite from the workpiece surface.

Abstract: A method and apparatus for fixturing an airfoil stub during linear friction welding are described. Critical clamping support structures are manufactured by a direct digital manufacturing process such as direct metal laser sintering to minimize time and expense of the process.

Abstract: A friction stir welding method of manufacturing a metallic housing including electronic device housing is described as follow. A first workpiece and a second workpiece made of metal are provided. The first workpiece is attached to the second workpiece. A joining tool is provided, which includes a shaft shoulder and a stir pin extending from a friction surface of the shaft shoulder. A diameter of the shaft shoulder is in a range from about 8 mm to about 15 mm. The first workpiece and the second workpiece are stirred and rubbed by rotating the joining tool, thereby forming the electronic device housing. The electronic device housing is anodized.

Abstract: An aluminum alloy material is welded by performing friction stir welding to form a welded section in an aluminum alloy welded component. The aluminum alloy material contains Mg: 0.3-6.0% (mass %, hereinafter the same), Cu: 0.2% or less, Si: 0.1% or less, Fe: 0.1% or less, the balance being Al and inevitable impurities. Second phase particles dispersed in the aluminum alloy material have a grain size of 5 ?m or less as observed with an optical microscopic. Because the second phase particles are homogeneously dispersed in a welded section equivalent portion of the aluminum alloy welded component as compared to other portions, variations in pit formation caused by etching during anodizing are reduced, thereby eliminating color tone variations in the anodized coating formed on the aluminum alloy welded component.

Abstract: The invention relates to a method for producing integrally bladed gas turbine rotors, especially of integrally bladed turbine rotors, wherein rotating blades (10) are joined to a rotor base (11) with the intermediate disposal of an adapter (14) in such a way that first an adapter is joined to a connecting section (15) of each rotating blade to be connected to the rotor base, and that subsequently each rotating blade (10) is joined to a connecting section (16) of rotor base (11) via adapter (14) connected to said blade. According to the invention, each adapter (14) is connected to connecting section (15) of the respective rotating blade (10) by welding, each rotating blade (10) being connected to the respective connecting section of the rotor base by inductive high-frequency pressure welding via adapter (14) connected to the blade.

Abstract: A method of welding that realizes enhancements of airtightness and watertightness at a weld area and a method of welding and method of friction stir welding that attain an enhancement of welding operation efficiency/speed. There is provided a method of welding including the first primary welding step of carrying out a friction stir welding on the abutting portion (J1) of metal members (1,1) from the surface (12) side of metal member (1) and the second primary welding step of carrying out a friction stir welding on the abutting portion (J1) from the reverse face (13) side of the member (1), wherein in the second primary welding step, the friction stir welding is performed while penetrating a stirring pin (B2) of rotation tool (B) in plasticized region (W1) formed in the first primary welding step.

Abstract: A method of welding that realizes enhancements of airtightness and watertightness at weld area and a method of welding and method of friction stir welding that attain an enhancement of welding operation efficiency/speed. There is provided a method of welding including the first primary welding step of carrying out a friction stir welding on the abutting portion (J1) of metal members (1,1) from the surface (12) side of metal member (1) and the second primary welding step of carrying out a friction stir welding on the abutting portion (J1) from the reverse face (13) side of the member (1), wherein in the second primary welding step, the friction stir welding is performed while penetrating a stirring pin (B2) of rotation tool (B) in plasticized region (W1) formed in the first primary welding step.

Abstract: A shaft-gear connection comprises a shaft and a shrunk-on gear that has an axial first section, attached by a first shrink-fit bond, and an axial second section, attached by a second shrink-fit bond. The second shrink-fit bond is greater than the first shrink-fit bond so that a greater maximum torque to be transmitted from the gear to the shaft by the second shrink-fit bond than by the first shrink-fit bond. An axial intermediate section, attached by a third shrink-fit bond, is located between the axial first section and the axial second section. Both a surface pressure and a maximum torque that can be transmitted by the third shrink-fit bond are greater than the surface pressure and the maximum torque that can be transmitted by the first shrink-fit bond, but are less than the surface pressure and the maximum torque that can be transmitted by the second shrink-fit bond.

Abstract: A metallic housing for an electronic device, the metallic housing includes a main body defining a receiving chamber for receiving electronic components and an opening communicating with the receiving chamber, and a covering plate positioned on the main body adjacent to a side of the main body. The covering plate is welded to the main body by friction stir welding and a welded region is formed on a side surface of the metallic housing such that the welded region is smooth with the main body and the covering plate. A method for making the metallic housing and an electronic device using the metallic housing is also disclosed.

Abstract: A method of friction welding a head part to a skirt part of a piston having a hollow cooling duct in which the internal connection surface of the first part to be welded is reciprocally arranged with an internal connection surface of the second part to be friction welded, so that they form a unsymmetrical contact area, so that the resulting weld of the first and the second parts produces a weld bead that is located predominantly outside of the hollow cooling duct. The unsymmetrical contact area can be formed by chamfered, angled edge surfaces that produce, for example, a wedge-shaped space, or partially matched, inter-fitting surfaces that remain out of contact and produce a gap at sides facing the hollow space.

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 provides a qualitatively-stable functionally gradient material precursor having gradient material composition, as well as a production method of the functionally gradient material precursor, at low cost. Further, the present invention provides a functionally gradient material having gradient material composition, or having both gradient material composition and gradient porosity, so as to achieve high-functionality; as well as a production method of the functionally gradient material. A functionally gradient material precursor is formed by the steps of: forming plural kinds of metal foam precursors, each obtained by performing heat treatment on a metal member so that a plurality of pores are generated within the metal member, by making the material composition of the metal member different; and friction stir welding the plural kinds of metal foam precursors. Further, a functionally gradient material is formed by performing heat treatment on the functionally gradient material.

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 piston rod manufacturing method for manufacturing a piston rod by joining together respective end surfaces of a rod main body and a rod head, includes a first step of hollowing out respective axial center portions of the rod main body and the rod head from the respective end surfaces thereof in order to remove impurities caused by center segregation, and a second step of joining together the respective end surfaces of the rod main body and the rod head by friction welding.

Abstract: The invention relates to the manufacture of protective coatings onto interior surface of long-length tubes or pipes having relatively small diameter, in order to prevent corrosion-, erosion-, or wear damage of said surface. The method for manufacturing a tube comprising an embedded corrosion-resistant and wear-resistant-coating, wherein the tube consists of an external tube layer, a bond layer, a corrosion- and wear-resistant coating, and an internal tube layer, includes: depositing the corrosion- and wear-resistant coating (CWRC) onto outer surface of the internal tube, depositing a bonding material onto CWRC, inserting the internal tube with deposited CWRC and bond material into the external tube to provide an embedded CWRC between external and internal tube layers, and bonding both tubes with the interior CWRC in one solid structure. A crack-healing compound or release compound is additionally deposited onto internal tube before CWRC, which is preferably alumina ceramic or hard thermal-sprayed alloy.

Abstract: A coaxial connector for interconnection with a coaxial cable with a solid outer conductor by laser welding is provided with a monolithic connector body with a bore. A sidewall of the bore is provided with an inward annular projection angled toward a cable end of the bore. A sidewall of the inward annular projection and the sidewall of the bore form an annular laser groove open to a cable end of the bore. The annular laser groove is dimensioned with a taper at a connector end of the laser groove less than a thickness of a leading end of the outer conductor. The taper provides an annular material chamber between the leading end of the outer conductor, when seated in the laser groove, and the connector end of the laser groove.

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: The invention utilizes vibration control, precision manufacturing tolerances for certain components of the system, and techniques for limiting thermal expansion of components, including passive insulation and active cooling techniques, in order to enable high speed tool rotation for Friction Stir Spot Joining of Advanced High Strength Steels.

Abstract: A method is taught for creating a hollow sphere that is created by joining two cylinders together that have a semispherical hollow formed in the ends being joined together, wherein a metallic reinforcing disk is inserted at an interface between the two ends of the cylinders, wherein the two cylinders and reinforcing disk are joined using friction stir welding to create an inner sphere from the two hemispherical hollows that is bisected by the metallic reinforcing disk, and wherein the joined cylinders and reinforcing disk are machined to thereby create an outer spherical surface that is centered around the inner sphere.

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.

Abstract: An electrochemical anode is formed using friction stir welded (FSW) joints. A FSW joint may be formed between the bus bar and anode sheet or the lead encapsulation and anode sheet. The FSW joints may also comprise fillet and butt joints. FSW joints may also be utilized to seal the ends of the electrochemical anodes to prevent corrosion.

Abstract: In a method of making a control arm, a middle piece is held in a mounting of a rotary friction welding machine so as to be constraint against rotation and movement in an axial direction. End pieces are rotated in synchronism on opposite ends of the middle piece so as to rub friction welding sites of the end pieces and friction welding sites on the middle piece on one another to initiate a friction welding process. After releasing the middle piece, the friction welding sites are compressed through axial displacement of at least one of the end pieces.

Abstract: A method of making a fluid cooled assembly that incorporates a base that forms a partial enclosure defining an interior void space and having a top wall that has a top surface and that defines at least one opening through the top wall to the void space, the base further defining fluid entrance and exit ports into the void space, the top wall being made of material that can be friction stir welded. A lid having a size and shape substantially conformal to the opening, having a top surface and a bottom surface that defines a set of downwardly extending pins, and that is formed of a material that can be friction stir welded to the base is placed into the opening so that the lid top surface is flush with the top surface of the base top wall and friction welding the lid to the base.

Abstract: A shadow frame and a method of manufacturing the shadow frame are disclosed. The shadow frame is utilized in photoelectrical semiconductor manufacturing processes and is utilized for fixing a glass substrate by combing with a support base used to carry the glass substrate. The shadow frame has a plurality of frame components and welding parts, and the frame components are adjoined at the welding parts to form the shadow frame. The provided shadow frame and its manufacturing method are capable of improving the utility rate of the substrate used to manufacture the shadow frame, avoiding a waste of the substrate, and thereby capable of reducing the manufacturing cost.

Abstract: This invention relates to a friction welding apparatus, and more particularly, but not exclusively, to a modular friction welding apparatus suitable for in-situ reparation of blind holes in pipes. The friction welding apparatus includes a frame assembly, a spindle assembly for holding a friction welding consumable; and a drive assembly for driving a spindle of the spindle assembly. The spindle assembly and the drive assembly are releasably securable to the frame assembly so as to form a modular friction welding apparatus, and the frame assembly is furthermore removable securable to an object to be welded.

Abstract: The invention relates to a method for producing integrally bladed gas turbine rotors, especially of integrally bladed turbine rotors, wherein rotating blades (10) are joined to a rotor base (11) with the intermediate disposal of an adapter (14) in such a way that first an adapter is joined to a connecting section (15) of each rotating blade to be connected to the rotor base, and that subsequently each rotating blade (10) is joined to a connecting section (16) of rotor base (11) via adapter (14) connected to said blade. According to the invention, each adapter (14) is connected to connecting section (15) of the respective rotating blade (10) by welding, each rotating blade (10) being connected to the respective connecting section of the rotor base by inductive high-frequency pressure welding via adapter (14) connected to the blade.

Abstract: A frictionally press-bonded member includes a steel pipe, and a stab. The steel pipe has opposite ends. The stab is frictionally press-bonded to at least one of the opposite ends of the steel pipe. The steel pipe is subjected to a normalizing treatment before being frictionally press-bonded to the stab.

Abstract: Two tubular components (10, 14) are provided with integral end caps (11, 15). The end caps (11, 15) are placed in abutting relationship and are held together under pressure whilst the tubular component (10) is rotated. A pressure is applied and this causes frictional heating. A friction welded joint (18) occurs at the interface between the two end caps (11, 15). On completion of the welding process a machining tool is then passed through the internal bore (12 or 16) in either of the tubular components. The machining tool cuts through the joined end caps (11, 15) to produce a single uniform bore thorough the joined components. In a further post processing operation the extruded flash (20) is removed from the outer surfaces (13, 17).

Abstract: A method for welding workpieces where at least two workpieces are welded together by means of friction stir welding, at least one of the workpieces being treated with ultrasound during the welding.

Abstract: A method of friction welding a head part to a skirt part of a piston having a hollow cooling duct in which the internal connection surface of the first part to be welded is reciprocally arranged with an internal connection surface of the second part to be friction welded, so that they form a unsymmetrical contact area, so that the resulting weld of the first and the second parts produces a weld bead that is located predominantly outside of the hollow cooling duct. The unsymmetrical contact area can be formed by chamfered, angled edge surfaces that produce, for example, a wedge-shaped space, or partially matched, inter-fitting surfaces that remain out of contact and produce a gap at sides facing the hollow space.

Abstract: In a process for friction stir welding together pieces of dissimilar material, a first piece of a second metal is overlaid onto a first piece of a first metal that is dissimilar from the second metal such that at least a portion of the first piece of second metal overlaps a portion of the first piece of first metal. A second piece of the first metal is placed in side-to-side relationship with the first piece of second metal and overlies another portion of the first piece of first metal. The relative arrangement between the second piece of first metal and the first piece of second metal define a joint line overlying the first piece of first metal. The first piece of first metal, the first piece of second metal, and the second piece of first metal are friction stir welded together along the joint line.

Abstract: In a method of making a control arm, a middle piece is held in a mounting of a rotary friction welding machine so as to be constraint against rotation and movement in an axial direction. End pieces are rotated in synchronism on opposite ends of the middle piece so as to rub friction welding sites of the end pieces and friction welding sites on the middle piece on one another to initiate a friction welding process. After releasing the middle piece, the friction welding sites are compressed through axial displacement of at least one of the end pieces.

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 method of mitigating distortion in a friction stir weld joint as well as an associated friction stir weld assembly for mitigating distortion in a friction stir weld joint are provided. In this regard, a workpiece having a friction stir weld joint and associated distortion may be provided. Force may then be selectively applied to the workpiece along at least a portion of friction stir weld joint. The application of force induces plastic deformation along at least the portion of the friction stir weld joint in order to reduce the distortion of the workpiece. Force may be applied, for example, by moving a roller, such as a hardened cylindrical roller having chamfered edges, along at least a portion of the friction stir weld joint in order to apply a compressive force.

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: An object of the present invention is to provide a disk brake and a method of making the disk brake capable of improving the efficiency of manufacturing a caliper. A bottom portion 41 of a bore 40 is formed by integrally welding an opening surrounding portion at the bottom portion 41 side of a cylinder portion 35 and a bottom cover member 92 fitted to the opening surrounding portion by friction stir welding. The bottom cover member 92 is formed into a disk shape, and provided with a protrusion 68 at one surface side facing the interior of the bore 40, and an inflow hole 58 for a supply of a fluid pressure into the bore 40 formed within the range of the protrusion 68 to establish communication between one surface 71 and the other surface 63.

Abstract: Two tubular components (10, 14) are provided with integral end caps (11, 15). The end caps (11, 15) are placed in abutting relationship and are held together under pressure whilst the tubular component (10) is rotated. A pressure is applied and this causes frictional heating. A friction welded joint (18) occurs at the interface between the two end caps (11, 15). On completion of the welding process a machining tool is then passed through the internal bore (12 or 16) in either of the tubular components. The machining tool cuts through the joined end caps (11, 15) to produce a single uniform bore thorough the joined components. In a further post processing operation the extruded flash (20) is removed from the outer surfaces (13, 17).

Abstract: The present invention provides a composite skin for the aeronautics and astronautics industries, and also a method for producing a composite skin of this type. The method comprises the following method steps: removing excess material from a butt plate to form a butt strap at one end thereof, subsequently connecting the other end of the butt plate to a skin plate with a substance-to-substance bond, and then fastening a further skin plate to the butt strap to form the composite skin. The idea behind the invention involves replacing a rivet connection with a substance-to-substance bond. This provides the advantage that the weight of the composite skin and the production costs for the composite skin are reduced.

Abstract: A method of processing heated metal logs in a metal extrusion process. The remainder of each log is attached to the succeeding log. Specifically, the abutted ends of the two log segments are aligned with a saw. The saw is actuated to simultaneously remove material from both of the abutted ends. The cut ends are friction welded together through relative rotation of the log segments. The process creates a heated log column that is effectively endless, eliminating log remainders.