Abstract: Illustrated and described is a friction stir welding device for mounting on a handling device. The object that the forces and moments which have to be absorbed by the handling device during the welding operation in the course of the movement of the friction stir welding tool along the weld seam are independent of the welding operation is achieved by a friction stir welding device with a tool drive, with a mounting element for connection to the handling device, with a friction stir welding tool, which is driven by the tool drive in a rotating manner about an axis of rotation, with a counterbearing roller and with a counterbearing drive, the counterbearing drive driving the counterbearing roller in a rotating manner about a counterbearing axis and the circumferential surface of the counterbearing roller being arranged opposite the friction stir welding tool.

Abstract: A method and apparatus is disclosed for forming a friction stir weld joint using a friction stir tool. A first metallic work material and a second metallic work material are provided and are substantially abutted to define a joint interface having a weld surface. A quantity of metallic donor material is provided and deposited into a depression formed in the weld surface along the joint interface. A friction stir welding tool having a shoulder and a pin depending from the shoulder is provided and applied against the donor material within the depression using a plunge force. The friction stir welding tool is rotated such that the pin contacts the donor material and heats the donor material to plasticize at least a portion of the donor material forming a friction stir weld joint. The friction stir welding tool is then urged along the joint interface.

Abstract: The purpose of the present invention is to provide a method that can be easily applied to friction stir welding where the thickness of face plates at one welding portion is different from the thickness of face plates at another welding portion. Three shape members 10, 11, 12 having two butt joint portions are mounted on a jig 15. The face plate 14 of shape member 10 is thick and the face plate 14 of shape member 12 is thin. The protruded height of projection 18 is greater at portion B where surface plates 14 being welded are thin than the protruded height of projection A where surface plates 14 are thick. The depths for inserting rotary tools to shape members 10, 11, 12 for friction stir welding are the same. Friction stir welding is facilitated since the size and insertion depth of all the rotary tools being applied can be the same.

Abstract: A friction stir welding (FSW) apparatus has an FSW tool adapted for joining work pieces supportable against a backing anvil. The FSW apparatus comprises a pair of clamping rollers maintained in substantially perpendicular relationship to the backing anvil as the FSW tool moves along the tool path. A roller pivot joint of the FSW apparatus maintains a cylindrical roller outer surface of each clamping roller in substantially parallel relationship to the top sides of the work pieces. The roller pivot joint may include a gimballing roller bearing to which the clamping roller is mounted. The roller bearing is universally movable in a variety of directions to maintain the perpendicular relationship of the clamping rollers relative to the backing anvil.

Abstract: A process is disclosed that creates a high shear rate in a workpiece using a head including a ring-shaped rotatable shoulder, a first pin and a second pin, both pins extending downwardly relative to the shoulder. The process includes coupling the workpiece to a table and rotating the first pin and the second pin in the same direction, wherein the first pin has a diameter, wherein a gap between the first pin and the second pin is less than the diameter. The head is plowed through the workpiece with the shoulder bearing downwardly against the workpiece and the first and second pin disposed in the first and second workpieces. The first pin rotates in a direction opposite the direction of the second pin in the gap to create a high shear rate of the workpiece within the gap.

Abstract: A friction welding method includes a step of friction welding a first workpiece and a second workpiece together by pressing the first workpiece against the second workpiece relatively while rotating the two workpieces relatively, and a step of annealing the friction welded workpiece at a position adjacent to a welded portion thereof with high frequency induction heating.

Abstract: An apparatus for friction stir welding is described that includes a stationary assembly having a bore therethrough, the bore having an inner diameter, and a rotational assembly having a welding end. At least the welding end of the rotational assembly extends through the bore. A portion of the rotational assembly is adjacent the inner diameter of the bore. At least one of the adjacent portion of the rotational assembly and the inner diameter of the stationary assembly are configured such that rotation of the rotational assembly will cause plasticized material from a welding process that has entered an area between the adjacent portion and the inner diameter to move towards a welding zone located proximate the welding end.

Abstract: The disclosed method & apparatus are for forming a fluid connection or tap through the wall of a pipeline, particularly intended for “hot tapping” of subsea pipelines. The method comprises fitting a connecting piece having a mounting surface which extends around the tap location and at least partially over the tap location and a connecting wall (2h) which surrounds the tap location to provide an opening adapted for subsequent connection of a conduit to complete a fluid connection. The connecting piece is bonded to the pipeline by friction stitch welding performed inside said opening. The material at the tap location is removed (AC indicates after cutting) to define an aperture and provide said fluid connection surrounded closely by the weld between the connecting piece and the wall.

Abstract: An apparatus for friction stir welding is described that includes a stationary assembly having a bore therethrough, the bore having an inner diameter, and a rotational assembly having a welding end. At least the welding end of the rotational assembly extends through the bore. A portion of the rotational assembly is adjacent the inner diameter of the bore. At least one of the adjacent portion of the rotational assembly and the inner diameter of the stationary assembly are configured such that rotation of the rotational assembly will cause plasticized material from a welding process that has entered an area between the adjacent portion and the inner diameter to move towards a welding zone located proximate the welding end.

Abstract: A friction stir welding apparatus capable of stably applying a pressure force without enlarging the apparatus, and a robot having thereof are provided. A rotating tool is provided with a rotational shaft and a hollow surrounding shaft is provided to surround the rotational shaft. The rotational shaft is movable along an axis-of-rotation and is rotated by a rotation drive motor about the axis-of-rotation. The surrounding shaft is rotatably supported by a main frame and an outer threaded portion is formed around the outer peripheral thereof to be threadedly engaged with a nut member. The rotating tool is rotatably supported by a header, and the header and the nut member are coupled together through a bracket. Therefore, when the surrounding shaft is rotated about the axis-of-rotation by the linear movement motor, the rotating tool is linearly moved through the nut member, the bracket and the header, and can apply a pressure force against work pieces.

Abstract: A plurality of anode foils (7) and a plurality of cathode foils (8) respectively having connecting portions (12a, 12b) are alternately arranged with insulating separators (9) interposed therebetween. The connecting portions (12a, 12b) of the stacked electrode foils (7, 8) are respectively connected and united electrically and mechanically by friction stir welding, thereby forming a capacitor element (5). The capacitor element (5) is housed in a case (2), and the connecting portions (12a, 12b) are respectively connected to a positive electrode external terminal (4) and a negative electrode external terminal (4).

Abstract: A process for solid state deposition of a material onto a workpiece includes the steps of providing a rod of metallic deposition material, exerting pressure at one end of the rod to move the metallic deposition material into a deposition zone, rotating the rod while the pressure is being exerted to generate frictional heat when the rod contacts a surface of the workpiece, and raising the temperature of the metallic deposition material to reduce the amount of frictional heat which needs to be generated during the rotating step and to produce a microstructure which is substantially free of porosity and which has a fine grain size.

Abstract: An ultrasonic stir welding device provides a method and apparatus for elevating the temperature of a work piece utilizing at least one ultrasonic heater. Instead of relying on a rotating shoulder to provide heat to a workpiece an ultrasonic heater is utilized to provide ultrasonic energy to the workpiece. A rotating pin driven by a motor assembly performs the weld on the workpiece. A handheld version can be constructed as well as a fixedly mounted embodiment.

Abstract: In a friction spot joint structure, a first plate member is pressed against a second plate member by using a rotary tool and a receiving member. A concave portion is formed by a rotating pin portion of the rotating tool, with an interface between the first plate member and the second plate member remained. In this time, the first and second plate members are allowed to plastic-flow, so that an annular bulging portion of the second plate member raised into the first plate member is formed around the concave portion.

Abstract: Friction plug welding methods and systems plug a hole extending through a component part from front and back faces thereof. A sacrificial plate having an opening therethrough may be positioned against the back face of the component part with assistance from a restraint part (which is also preferably provided with a space of sufficient dept to receive a terminal end of the male plug) so that the opening is coaxially aligned with the hole to be plugged. Upon advancing a male plug of a plug rod into the hole under friction plug welding conditions, a friction weld region will therefore be formed between the male plug and defining surfaces of both the hole extending through the component part and the opening extending through the sacrificial plate. The plug rod may include an annular shoulder flange which defines a plane parallel to the front face of the component part so that flash flow from the friction welding will be displaced laterally of the hole. The male plug may be frustroconically shaped.

Abstract: A friction stir welding apparatus (120) brings end faces (1, 2) of a plate material (W1), having fingers (7a through 7d) at corners thereof, into abutment against each other to form a hollow cylindrical body (W2), and friction-stir-welds the end faces (1, 2) to each other. The apparatus includes a base (122), a first support device and second support device which are mounted on the base (122), a support core (32) spaced from the base (122) by the first support device and the second support device, for insertion into the hollow cylindrical body (W2) and for supporting the hollow cylindrical body (W2), and a first gripping member (238) and a second gripping member (268) disposed on the support core (32) for gripping respective protrusions (8, 9), which are formed when the fingers (7a through 7d) are held in abutment against opposite ends of abutting regions of the hollow cylindrical body (W2), and which extend along a joining direction.

Abstract: A joining method for joining together a first member having a circular hole and a second member having a circular portion fitted into the circular hole, at and around an entire annular joint interface between a circumferential wall of the circular portion and a circumferential wall of the circular hole. The joining method includes: preparing a clamp apparatus having a clamp body and a presser member attached to the clamp body in a manner rotatable about an axis of the circular hole of the first member; and joining the first and second members together at and around the annular joint interface therebetween while clamping the second member by the presser member so as to prevent movement of the second member in relation to the first member and rotating the first and second members about the axis of the circular hole of the first member.

Abstract: There is provided a friction stir spot joining device wherein stirring-related members are unitized to form a unitized stirring unit and an opening is formed in a friction stir spot joining device body for housing the unitized stirring unit therein. A stirring motor, a stirring shaft and a power transmission mechanism are unitized to form a stirring unit, and bearings of an LM guide (registered trademark) are fixed to the stirring unit immediately under the stirring unit, and a ball nut is fixed to the back face of the stirring unit, wherein the friction stir spot joining device body is opened to form the opening at a rear upper portion through which the stirring unit is caused to move inside thereof.

Abstract: The invention relates to a method for the joining of tube plates (10) and tubes (11) in a tube bundle heat transfer device with the help of a rotating friction tool. Here, the friction tool is rotatingly moved into the open end of a tube (11) surrounded by the tube plate (10) in the axial direction of said tube and pressed against the face of the tube (11) in the manner that the tube end (12) and the region of the tube plate (10) surrounding the tube end are plasticised and merge into a weld joint.

Abstract: An apparatus for a friction stir and a friction stir processing of the present invention suppress an occurrence of a surface defect in an area processed by the friction stir. The apparatus for the friction stir includes a tool having a columnar tip-side part, a rotating unit for rotating the tool on a central axis, a first pressing unit for pressing a tip of the tool rotated by the rotating unit against a work, a jig having a tool insertion hole into which the tip-side part of the tool is inserted so that the tip-side part of the tool is encircled around the jig, a second pressing unit for slidably pressing the jig against the work, and a press control unit for controlling the first pressing unit so that the tip-side part of the tool is gradually pulled out of the work by the first pressing unit while moving the tool and the jig relative to the work, in a state that the tool is rotated by the rotating unit and the tip of the tool has been sunk into the work to a predetermined depth by the first pressing unit.

Abstract: Device for joining faces of parts having great longitudinal extension by friction welding. The device includes first and second clamping arrangements structured and arranged to position ends of the parts against one another. At least one of the first and second clamping arrangements is axially movable with respect to another of the first and second clamping arrangements. At least one of the first and second clamping arrangements is movable along a direction that is parallel to a part cross-sectional plane defined by an end face of one of the parts.

Abstract: Friction-stir weldments and systems and methods for producing the same are disclosed. In one embodiment, a metal product includes a first metal plate having a first center-neutral axis, a second metal plate comprising a second center-neutral axis, and a friction-stir corner weld that connects the first metal plate to the second metal plate, where the first center-neutral axis of the first metal plate is transverse to the second center-neutral axis of the second metal plate. In another embodiment, a system for producing friction-stir weldments includes a backup anvil having a first supporting face and a second supporting face, where the first supporting face is adapted to receive and support the first metal plate, and where the second supporting face is adapted to receive and support a second metal plate, wherein the center-neutral axis of the first metal plate is transverse to the center-neutral axis of the second metal plate.

Abstract: This invention provides a method for inspecting a joined region and joining strength of a joined object formed by a spot friction stir joining process. In this method, an ultrasonic wave is introduced into the joined object from a backing face 25 opposed to a joining tool plunging face 24 and the ultrasonic wave reflected from the joined object 20 is taken in. In this case, the joining region 21 and the joining strength is estimated by observing a reflected wave of the ultrasonic wave in the vicinity of a position, along a reference direction Z, corresponding to an interface 27 of two joining members, without using the reflected wave of the ultrasonic wave reflected from the joining tool plunging face, thereby inspecting the joined object based on the estimation result.

Abstract: An embodiment of a method for interconnecting tubular sections includes the steps of vertically positioning a second tubular above a first tubular forming a seam defined by a bottom end of the second tubular and a top end of the first tubular; positioning a friction stir welder (FSW) proximate to the seam; aligning the first tubular and the second tubular to form a longitudinal axis; and guiding the FSW along the seam forming a weld joint.

Abstract: An apparatus and method are provided for measuring loads on a rotating friction stir welding tool of a friction stir welding machine. The apparatus includes a frame that can be connected to the friction stir welding machine, and rollers rotatably connected to the frame are structured to contact and rotate with the friction stir welding tool. Each roller is adapted to adjust in a respective direction and communicate with a respective load cell so that the load cells detect a positional characteristic of the rollers and measure loads applied to the rotating friction stir welding tool during operation. The rollers can contact the rotating tool directly during operation of the machine, such as while the rotating tools is being moved through a workpiece to form a friction stir weld joint, to measure the loads on the tool in the direction of movement of the tool and a direction normal to the movement, i.e., the path and path normal directions.

Abstract: In the third step of joining of the metal members, the pressing force of the rotational tool under rotation is maintained at the third pressing force that is smaller than the second pressing force until a specified period of time elapses after the tip of the pin portion of the rotational tool has reached the specified point that is at a distance from the joining face. Accordingly, the proper plastic flow of the metal member can be generated and thereby the joining strength with a sufficient period of time of agitation can be ensured, by maintaining a high temperature enough to soften the metal member and by preventing the rotational tool from coming into the metal member too deeply or from penetrating the metal member.

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

Abstract: A tool assembly which is particularly suitable for friction stir welding applications. The tool assembly includes a holder having an axis and one end adapted to be rotatably driven by a rotary drive mechanism about the holder axis. A tool having an axis is also provided and includes a tool tip at one end. A fastener detachably and coaxially secures the holder and tool together. This fastener includes a first part secured to the second end of the holder and a second part secured to the second end of the tool.

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

Abstract: Portable friction stir welding apparatus having a crawler which supports a motor for rotating a Friction Stir Welding tool and is coupled to a drive mechanism for urging the crawler along a predefined weld path on work pieces. The crawler can comprise one member or a set of two or three physically separated members each rotatably coupled to the friction stir welding tool. When one member is used to make a weld, it is located on top of the work pieces. When two members are used to make a weld, one member is located on the top of the work pieces and the second member is located on bottom of the work pieces. When three members are used to make two welds simultaneously on an upper work piece and a lower work pieces, one member of the crawler is located on the top surface of the upper work piece, a second member is located between the two work pieces, and a third member is located on the bottom surface of the lower work piece.

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

Abstract: In the friction stir joining apparatus of the present invention, a rotation control unit variably controls a rotational speed of a rotor; and a straight movement control unit controls a straight movement of the rotor so as to control a pressure applied by the rotor to the object. The tip portion of the rotating rotor is pressed against a workpiece, thus spot joining is executed. The apparatus can execute frictional stirring joining without practical trouble under simple control.

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

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

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

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

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

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

Abstract: A friction stir welding apparatus (120) brings end faces (1, 2) of a plate material (W1), having fingers (7a through 7d) at corners thereof, into abutment against each other to form a hollow cylindrical body (W2), and friction-stir-welds the end faces (1, 2) to each other. The apparatus includes a base (122), a first support device and second support device which are mounted on the base (122), a support core (32) spaced from the base (122) by the first support device and the second support device, for insertion into the hollow cylindrical body (W2) and for supporting the hollow cylindrical body (W2), and a first gripping member (238) and a second gripping member (268) disposed on the support core (32) for gripping respective protrusions (8, 9), which are formed when the fingers (7a through 7d) are held in abutment against opposite ends of abutting regions of the hollow cylindrical body (W2), and which extend along a joining direction.

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

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

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

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

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

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

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

Abstract: A preform and method for forming a structural assembly are provided. The preform can be formed by friction welding structural members to a base member and subsequently providing a connection material to join the structural members. The resulting preform can be formed with dimensions and a configuration that approximate the dimensions and configuration of the structural assembly. Thus, the structural assembly can be formed by joining multiple members that are generally smaller than the finished assembly.

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

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

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