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

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

Abstract: A spindle unit (A) for effecting a manufacturing or repair procedure includes a spindle assembly (2) having a spindle (12) that holds a tool (B), an electric motor (4), and a friction drive transmission (6) located between the spindle assembly and the motor. The transmission includes a sun roller (86) driven by the motor, an outer ring (110) coupled to the spindle, and a pair of support rollers (90) located between the sun roller and outer ring to position the outer ring eccentric to the sun roller and create a wedge gap (126) between the sun roller and the outer ring. The transmission also has a loading roller (96) located at the wedge gap such that it can displace laterally and lodge tightly in the wedge gap. The spindle rotates in bearings (14, 16), one of which is a single row tapered roller bearing that transfers thrust loads developed during the procedure.

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

Abstract: A friction welding process providing a workpiece having a weld surface, and a second workpiece having a weld surface. The workpieces being welded together at respective weld surfaces. Oscillatory motion is affected to the workpieces such that one weld surface moves across the other, thereby raising the temperature at the weld surfaces to create a weld interface. The oscillatory motion is ceased and the weld surfaces cool to weld the workpieces together at the interface. The workpiece has an extending portion, and the weld surface is provided on the extending portion. The extending portion includes an apex region, which engages the second workpiece's weld surface. A side face extends from the apex region to provide a gap between the side face and the second workpiece's weld surface. The gap allows weld flash material to pass from the weld interface through said gap.

Abstract: A method of friction stir welding and a non-consumable multi-section faced retractable shoulderless variable penetration friction stir welding tool. The tool includes a substantially cylindrical body portion, a head portion, and a tip section, each integral to the tool. The body portion has a longitudinal axis about which it is rotable, a diameter, a sidewall substantially parallel to the longitudinal axis, a proximal end, and a distal end. The head portion is located at the distal end of the body portion. The head portion includes a multi-section face, having a first face section and a second face section, that converges to the tip section. The tool is retractable, reduces overheating, improves weld quality by reducing internal voids and lack of fusion, and facilitates variable penetration welds.

Abstract: A method of friction stir welding and a non-consumable retractable shoulderless variable penetration friction stir welding tool. The tool includes a substantially cylindrical body portion, a head portion, and a tip section, each integral to the tool. The body portion has a longitudinal axis about which it is rotable, a diameter, a sidewall substantially parallel to the longitudinal axis, a proximal end, and a distal end. The head portion is located at the distal end of the body portion. The head portion has a base with a diameter substantially equal to the diameter of the body portion thereby forming a smooth transition between the body portion and the head portion, thus the tool has no shoulder. The head portion includes a face that converges to the tip section. The tool is retractable, reduces overheating, improves weld quality by reducing internal voids and lack of fusion, and facilitates variable penetration welds.

Abstract: An apparatus and methods for clamping around a manufacturing tool engaging a work piece are described. In one embodiment, a clamp includes a moveable support arranged to at least partially surround a circumference defining a work area. A friction reducing element is attached to the support to apply pressure to the surface when the clamp is engaged with the work piece, and to allow the clamp to be moved with the manufacturing tool. In accordance with other aspects of the invention, the clamp co-annularly or partially surrounds the manufacturing tool. In another embodiment, the manufacturing tool is a friction stir welding tool.

Abstract: In a first step, a roof panel and a front header are joined at plural frictional spot joint portions at a front-end frictional joint area, and the roof panel and a rear header are joined at plural frictional spot joint portions at a rear-end frictional joint area. The roof panel and a side roof rail are joined at plural frictional spot joint portions at left-side and right-side frictional joint areas. Subsequently, in a second step, the members are joined at the plural rivet joint portions at a border area of the above-described joint areas, and the members are joined at plural rivet joints at a bounder area of the above-described joint areas. Accordingly, there can be provided a joining method and structure of metal members that can properly reduce deformation due to a thermal strain.

Abstract: A friction stir welding tool includes an integral shank-pin unit and a shoulder attached to the shank-pin unit.

Abstract: There is provided a method for welding together two metal components to form a large structure suitable for use as an aerospace component. The method comprises the steps of providing two metal components to be welded together, each component having a length, a width, a height and a surface to be welded, the surface to be welded of at least one of the metal components including a feature extending substantially the length of the component, the feature reducing the contact width of the surfaces to be welded of the two components to less than the width of each component; and welding together the components. There is also provided a large structure so created. There is also provided a method for welding together two metal components to form a part or a whole of a spar for a wing for an aircraft and a spar so created.

Abstract: A method of mounting a semiconductor chip in which an IC chip is mounted by filling a gap between the chip and a substrate with adhesive which functions as an underfill. The fillet of the underfill is made to have a preferable shape. To accomplish this, a head IC chip provided with bumps is placed on a suspension that is covered with the underfill adhesive and is provided with pads. A bonding tool presses the head IC chip and applies ultrasonic oscillation to the head IC chip, so that the bumps are properly bonded to the pads. When the head IC chip is pressed and subjected to ultrasonic oscillation, the ultraviolet rays 108 are emitted so as to harden the peripheral portion 151a of the adhesive 151 spread out between the head IC chip 11 and the suspension 12.

Abstract: There is provided a friction stir spot joining device in which a pin can be simply and surely caused to come in or come out from a tip end of the joining tool by driving a pin extraction motor. The friction stir spot joining device softens and stirs works to be joined by frictional heat generated by the rotation of a pin so as to perform spot joining and is provided with a stirring motor for rotating a joining tool having a pin, and a pressure application motor for linearly driving the joining tool. The friction stir spot joining device further has a pin extraction motor which is disposed at the rear of a stirring motor on the same axis line as the stirring motor and integrated with the stirring motor.

Abstract: A fracture resistant friction stir welding tool includes a pin for plunging into one or more workpiece(s) to be welded and a shoulder for preventing plasticized material from flowing out of the joint being welded. The friction stir welding tool includes a tool body including a cavity for receiving the shoulder and exerting a compressive stress on the shoulder, and the pin is placed in compression by an axial tension member in the pin.

Abstract: An object of the present invention is to provide a friction stir welding tool which enables friction stir welding of a wide range of materials, from low-melting temperature metallic materials including aluminum to high-melting temperature metallic materials including steel. An entire friction stir welding tool or a tool tip including a pin is made of Mo alloy having a dual phase microstructure of Mo and intermetallic compound Mo5SiB2. It is desirable that the Mo alloy be composed of 6.0 to 10.0 mol % of Si, 10.0 to 20.0 mol % of B, and 20 to 60% of Mo-phase volume content. This Mo alloy tool has excellent high-temperature strength and wear-resistance properties and hardly deform and wear when used for the welding of steel.

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 (22) is provided with a rotational shaft (26) and a hollow surrounding shaft (27) is provided to surround the rotational shaft (26). The rotational shaft (26) is movable along an axis-of-rotation (L) and is rotated by a rotation drive motor (25) about the axis-of-rotation (L). The surrounding shaft (27) is rotatably supported by a main frame (29) and an outer threaded portion is formed around the outer peripheral thereof to be threadedly engaged with a nut member 53. The rotating tool (22) is rotatably supported by a header (40), and the header (40) and the nut member 53 are coupled together through a bracket (70).

Abstract: A recess portion with a substantially circular cross-section is provided in the upper end surface of a supporting jig. When a probe of a device for friction stir welding is buried in the upper end surface of a layered portion, material in the vicinity of the buried portion flows plastically. This causes the plastically flowed material to flow into the recess portion, and as a result, the material is stirred in a relatively large region. When the material that flowed into the recess portion is cooled and solidified, a friction stir-welded portion-possessing member having a projection portion is obtained.

Abstract: In a spot joining method and apparatus, pressing force of a rotating tool is maintained at a first pressing force, the frictional heat due to the rotation of the rotating tool is generated on a surface of an aluminum plate, and the aluminum plate is softened by this frictional heat, so as to ensure the centering of a pin portion of the rotating tool. Thus, even if the pin of the rotating tool is short, a stable joining position can be obtained, so that the aluminum material can be prevented from accumulating on the rotating tool, the appearance of joining surfaces can be prevented from deteriorating, and the sufficient joining strength can be obtained.

Abstract: A friction stir welding tool is described and which includes a shank portion; a shoulder portion which is releasably engageable with the shank portion; and a pin which is releasably engageable with the shoulder portion.

Abstract: Systems and methods for verifying a materials processing path on a work piece are described. In one embodiment, a system for verifying a material process path on a work piece includes a processing unit operable to receive processing instructions to control a motion of a machine tool device relative to a work piece. A tool holder of the machine tool device retains a tool path tracing assembly that applies a mark to a surface of the work piece as the assembly is moved along the material process path.

Abstract: A method of making tailored blanks in accordance with one embodiment comprises the steps of friction welding a first joining surface of a first structural member having a substantially non-rectangular parallelogram profile to a first portion of a joining surface of a substrate; and thereafter concurrently linear friction welding first and second joining surfaces of a second structural member having a substantially non-rectangular parallelogram profile to a second portion of the surface of the substrate and to a second joining surface of the first structural member respectively. The first and second portions of the surface of the substrate are adjacent. Two or more structural members having a substantially non-rectangular parallelogram profile can be linear friction welded in succession to the substrate and to each other, thereby building a structural assembly having a long flange or other long feature of a desired length.

Abstract: An assembly for positioning a structural assembly for friction stir welding, and a system and method for friction stir welding the structural assembly are provided. The assembly includes an engaging structure and at least one tooling block capable of engaging the engaging structure, as well as a substructure positioned adjacent to the engaging structure and tooling block. The substructure and engaging structure capable of being friction stir welded together to form a butt joint therebetween.

Abstract: A bonding structure for a container member is disclosed. The container member has an opening and a covering member for covering the opening. The container member and covering member are abutted with each other and bonded by a friction stir welding operation. The bonding structure for the container and covering members comprises a bonding portion and a backing member. The bonding portion of the container member and the covering member is formed by inserting a friction stir welding tool into an abutting portion of the container member and the covering member. The backing member is provided for obstructing a plastic flow of materials for the container member and the covering member when the friction stir welding operation is performed. The backing member is disposed adjacent to the bonding portion, at a side of the abutting portion that is opposite to an inserting side of the friction stir welding tool.

Abstract: An apparatus for friction stir welding, a weld tool for friction stir welding, and a method for making a weld tool for friction stir welding are presented. The weld tool comprises doped tungsten. A method for manufacturing an article, where the method comprises providing the apparatus for friction stir welding, and the article produced by this method are also presented.

Abstract: The present invention is a friction stir welding machine adapted to perform solid phase welding on a welding portion of materials to be welded, by pressing a welding tool against the welding portion of the materials to be welded while rotating the welding tool, and forcing the welding tool to be advanced into a softened portion which is softened by a frictional heat while stirring the softened portion, wherein a coating made of aluminum nitride is formed on at least a region of the welding tool to be in contact with the materials to be welded.

Abstract: A joining portion of an opposed surface of workpieces is heated by generating an induced current due to a change of a magnetic field as well as by applying a frictional heat to the joining portion, so that productivity and quality of welding can be improved.

Abstract: There is provided a friction stir spot joining device to eliminate the generation of tipping torque caused by a pressing force by allowing the axis of a ball screw for generating the pressing force and the center of a shaft of a stirring motor to be coincident with each other, thereby allowing the device to be downsized and the device to effect joining operation with ease. The friction stir spot joining device comprises a ball nut fixed to the rear end side the stirring motor, a hole is defined in an output shaft of the stirring motor in which the ball screw is housed from a rear portion of the hole so as to be positioned in the hole, wherein a rotating force of the pressing motor is transmitted to the ball screw and the stirring motor is moved forward and backward by the ball nut threaded with the ball screw.

Abstract: A friction stir welding tool having a shoulder section with a scroll pattern that terminates prior to the edge or boundary of the shoulder section to create a scroll-free concentric surface area.

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: The invention is directed to a friction stir welding tool cleaning method and apparatus for fixed and retractable pin tools. The method and apparatus use a heating component, a temperature indicator component, a controller component, and a rotatable tool cleaner component for cleaning fixed pin tools. An additional bore cleaner component is used for cleaning retractable pin tools. Heat is applied to a friction stir welding tool having a surface with weld process residue material until the process residue material is sufficiently plasticized, and then the tool cleaner component is applied to the heated tool to remove the plasticized residue on the pin and shoulder surfaces of the tool, and for retractable pin tools, the bore cleaner component is applied to the heated tool to remove the plasticized residue in the tool bore.

Abstract: A friction stir tool has an axis of rotation and a welding tip that is made of powdered metal material.

Abstract: The apparatus includes a base 23 fixed at a predetermine position, a tool holding jig 29, to which a welding tool 21 is mounted, installed on the base 23 rotatably about a preset reference axis L1 and movably along the reference axis L1, a tool rotation driving means for rotating the tool holding jig about the reference axis L1, and a tool movement driving means for moving the tool holding jig along the reference axis L1. The apparatus realizes miniaturization of the apparatus, simplification of the structure, and improvement of the operability.

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

Abstract: A method of repairing a discrepancy in a casting, weldment or other workpiece comprised of a material characterized by thermoplastic properties includes excising the discrepancy by cutting, milling, or otherwise removing workpiece material surrounding the discrepancy so as to remove the discrepancy and form a cylindrical hole in the workpiece. The method further includes placing a cylindrical plug in the cylindrical hole and moving a friction stir welding tool around the circumference of the plug to weld the plug to the workpiece.

Abstract: A friction stir weld tool sleeve is supported by an underlying support pin. The pin material is preferably selected for toughness and fracture characteristics. The pin sleeve preferably has a geometry which employs the use of an interrupted thread, a plurality of flutes and/or eccentric path to provide greater flow through. Paddles have been found to assist in imparting friction and directing plastic metal during the welding process.

Abstract: Method and apparatus for friction welding termination elements at first and second ends (21, 23) of a cylindrical shaft (15) in alaignment with an axis. A shaft receiver (17) receives the cylindrical shaft (15), and a first chuck (70) grips and rotates the cylindrical shaft (15) in alignment with the axis. A second chuck (75) grips the cylindrical shaft (15) and translates the second chuck (75) between first and second axial positions. A first termination receiver (155) receives the first termination (30) and axially translates same to a first installation position. An installation drive (90) urges the first termination (30) axially toward the cylindrical shaft (15) as it is rotated. A second termination receiver axially translates second termination (32) to a second installation position in allignment with the axis. A second installation drive (91) urges the second termination element (32) axially toward the cylindrical shaft as it is rotated.

Abstract: A system and method for performing friction stir welding of non-planar materials having high melting temperatures, wherein a process is provided for performing longitudinal and radial welds on objects such as pipes, flanges, tanks, and shrouds, and wherein an active or passive mandrel provides support for the friction stir welding process.

Abstract: The process for metallically connecting the faces of rods. Axially normal dressing at least two rod free ends, then placing the cross sectional surfaces of the rod free ends one against another under pressure. Oscillating the two rod free ends in the opposite direction to one another, whereby frictional heat is generated on the contact surfaces of the rod free ends. Further, when the conditions for a metallic connection are met, the rod free ends are axially aligned and the pressurization of the cross sectional areas is increased. Resulting in the rod free ends being connected to one another over the entire surface. The instant abstract is neither intended to define the invention disclosed in this specification nor intended to limit the scope of the invention in any way.

Abstract: A system and associated friction stir welding (FSW) assembly, controller and method for performing a friction stir welding operation are provided. The friction stir welding system includes a FSW device, such as a CNC machine, that includes an actuator capable of moving a FSW tool relative to a workpiece. The system also includes a controller capable of controlling the FSW device to drive the actuator to move the FSW tool. In this regard, the actuator is capable of being driven such that the FSW tool is capable of performing a friction stir welding operation on the workpiece. The controller is capable of monitoring a torque of the actuator to thereby control the FSW device to drive the actuator such that the torque is maintained within a range about a torque setting.

Abstract: Face plates 11 and 12 of a hollow shape member 10 are abutted against face plates 21 and 22 of a hollow shape member 20. Grooves 18 formed to said face plates 11 and 12 at the abutted region receive projections 28 formed to said face plates 21 and 22. A connecting plate 14 orthogonal to said face plates 11 and 12 is provided to the hollow shape member 10. There is no connecting plate orthogonal to face plates 21 and 22 disposed on the end of the hollow shape member 20. Friction stir welding heat causes the face plate 21 (22) to move toward the thickness direction of hollow shape members 10 and 20, but such movement is suppressed by the groove 18 and projection 28. Thereby, the abutted region is welded flatly. Since the hollow shape member 20 requires no connecting plate corresponding to plate 14, the welded members are light in weight.

Abstract: An apparatus is proposed for connection of workpieces using the friction stir welding method, with a shaft (33, 33?) which can be driven such that it rotates and at whose end remote from the drive end of the shaft a pin-like projection (8) is arranged, at whose end a first stop, which is formed by a first shoulder (6), is arranged, with the first shoulder having a diameter which is larger than the diameter of the pin-like projection (8), and with a second stop (7, 7?), which is formed from a second shoulder and is arranged such that the workpieces (19) to be connected can be enclosed between the stops (6, 7, 7?), in that at least one of the stops can be moved translationally in order to enclose the workpieces (19) with a predetermined force in the direction of the other stop.

Abstract: A system and method of using friction stir welding and friction stir processing to perform crack repair or preventative maintenance of various materials and structures, wherein the structures include pipeline, ships, and nuclear reactor containment vessels, wherein the friction stir welding and processing can be performed on various materials including metal matrix composites, ferrous alloys, non-ferrous alloys, and superalloys, and wherein the friction stir welding and processing can be performed remotely and in harsh environments such as underwater or in the presence of radiation.

Abstract: A structural assembly and a preform and method for forming the structural assembly are provided. The preform can be formed by linear friction welding structural members to a base member and friction welding each structural member to at least one of the other 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: A surface of an article is heated and subjected to pressure by operation of a friction stir tool. The pressure of the face of the tool on the article surface, and the speed of rotation of the tool and of its progression along the surface of the article, are controlled to progressively hot-work a specified surface area. The face of the tool may be round and have a profiled, axially extending, smaller diameter pin for higher concentration of frictional heat and load and for plasticizing a surface layer of the workpiece. Such hot work may be applied for reducing surface porosity or for producing another change in the surface microstructure, or for effecting another change in surface material properties.

Abstract: In an electronic component mounting method in which electronic components are sucked/held by plural respective nozzles provided on a mounting head so as to be mounted on electronic component mounting portions of a board, such a mounting operation is sequentially carried out as to all of the electronic components, in which the electronic components are sucked/held by the plural nozzles; an electronic component sucked/held by one of the plural nozzles is provisionally positioned above one electronic component mounting portion; both this electronic component and the electronic component mounting portion are observed by an observation head which is located between the board and the mounting head; a relative position detecting operation for detecting a relative positional relationship between this electronic component and the electronic component mounting portion is carried out as to all of the electronic components held by the mounting head; and the electronic component is positioned with respect to the electroni

Abstract: A friction stir welding (FSW) travel axis load control method and apparatus for controlling a travel axis load applied to a FSW setup during the joining of workpieces by FSW. The method and apparatus recognize that controlling certain attributes of a friction stir welding plasticized region are key to controlling the quality of the resulting weld. This invention controls any of a number of qualities associated with the plasticized region thereby producing welds having improved mechanical and aesthetic properties, as well as extending the life of the FSW tool. The method and apparatus may control the FSW process to obtain a predetermined optimum size of a heat affected zone. The plasticized region may be monitored in a number of ways including, but not limited to, force on the tool, torque applied to the tool, workpiece temperature, plasticized region physical dimension, as well as changing surface characteristics such as color and reflectivity.

Abstract: A method and device enabling friction stir welding along non-linear joint lines or seams on either planar or non-planar surfaces are provided. The device features four roller clamps located on upper and lower pieces. It also contains a non-consumable tool with a profiled probed end that engages work pieces and follows along a non-linear or linear joint lines in order to achieve high-integrity friction stir welds. No special anvil is required and the device can be manually or automatically operated and controlled. Operating similarly to a conventional sewing machine, this device and process enable an operator or user to manually guide work pieces to be welded through a friction stir welding tool and allows for flexibility in the path of the weld and the types of material being welded.

Abstract: A superplastically formed structural assembly is provided, as is an associated preform and method for forming such an assembly. The assembly includes a skin member and a support member that are joined to define a space between the members and between the joints. The assembly can be produced by joining the members in a flat configuration, and then forming the resulting preform to a predetermined shape of the structural assembly. The support member defines at least one aperture in communication with the space between the members. Thus, the skin member can be formed by delivering a pressurized fluid through the support member to the skin member, e.g., to superplastically form the skin member against a die that defines a contour surface corresponding in shape to the predetermined configuration of the assembly. The support member can extend in a substantially direct configuration between opposing portions of the skin member.

Abstract: A tool for making simultaneously a plurality of parallel friction stir welds includes at least one shank for holding in a chuck or collet of a friction stir welding machine, a plurality of friction stir welding pins, and friction stir welding shoulders including at least four working surfaces adjacent said pins, the shoulders and pins mounted in axial relationship; dimensions of said friction stir welding pins and shanks corresponding to dimensions and spacings of said friction stir welds.

Abstract: A spin weld pin according the principles of the present invention can be rotated at a high speed relative to two or more framing members by a torque transmitting device. An axial force is applied to the pin as it rotates so that the pin contacts the framing members and generates frictional heat. The heat generated causes the framing members to enter a molten state and allows the pin to penetrate therethrough. Rotation of the pin is ceased and as the pin and framing members cool, a bond is formed that joins the framing members and pin together.