Including Means To Provide Heat By Friction Between Relatively Moving Surfaces (i.e., Friction Welder) Patents (Class 228/2.1)
  • Patent number: 7165710
    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.
    Type: Grant
    Filed: June 21, 2002
    Date of Patent: January 23, 2007
    Assignee: Black & Decker Inc.
    Inventor: Michael L O'Banion
  • Patent number: 7163136
    Abstract: A tool for forming a friction stir weld joint in a workpiece is provided. 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. In particular, the stirring portion of the pin defines at least one groove and ridge, each of which extend generally circumferentially around an axis of the pin. The tool can also include a second shoulder opposing the first shoulder such that the pin extends therebetween.
    Type: Grant
    Filed: August 29, 2003
    Date of Patent: January 16, 2007
    Assignee: The Boeing Company
    Inventor: George D. Hempstead
  • Patent number: 7156275
    Abstract: Welding head 1 for friction stir welding, adapted for connection and driving of a tool 2 intended for simultaneous friction stir welding from two opposite surfaces on an object for welding, comprising a tool holder 9, a force-generating device 3, 13 and a rotary driving device 5 which, during operation, can impart to the connected tool 2 a cyclic movement around the centre axis 10 of the tool and relative to the object for welding arranged in conjunction with the welding head. The force-generating device is controllable during operation and adapted so as, during operation, to act between a primary shoulder 6 and a secondary shoulder 7 on a tool 2 connected in the tool holder 9. The invention also comprises a welding system for friction stir welding, with the force between the shoulders of the tool being controlled depending on the current torque for rotary driving. Also indicated are a method for initiating friction stir welding and computer program for such a method.
    Type: Grant
    Filed: February 3, 2003
    Date of Patent: January 2, 2007
    Assignee: ESAB AB
    Inventor: Rolf Larsson
  • Patent number: 7156276
    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 a frame defining an aperture therein, and at least one structural member positioned within the aperture. The assembly also includes at least one spacer positioned within the aperture such that the spacer and structural member substantially fill the aperture to secure the structural member within the frame, as well as a substrate secured to the frame and positioned adjacent to the structural member in an overlapping configuration to define an interface between the substrate and structural member. In this configuration, the substrate and structural member are capable of being friction stir welded together.
    Type: Grant
    Filed: July 22, 2004
    Date of Patent: January 2, 2007
    Assignee: The Boeing Company
    Inventor: Kevin T. Slattery
  • Patent number: 7156277
    Abstract: A friction stir welding (FSW) method and apparatus are provided by which power needed for FSW is reduced and a compact FSW tool can be used. In the FSW method, metal members are lapped one on another and a rotating probe of an FSW tool is inserted into a contact portion of the metal members. The contact portion is softened by frictional heat and stirred by the probe so that the metal members are welded together. A portion of the metal members surrounding the probe is heated by a heater.
    Type: Grant
    Filed: August 23, 2005
    Date of Patent: January 2, 2007
    Assignee: Mitsubishi Heavy Industries, Ltd.
    Inventors: Soichiro Ishikawa, Haretaro Hidaka
  • Patent number: 7150389
    Abstract: The invention concerns a friction stir welding method according to which the workpieces (2, 3) to be welded are positioned on a worktable (7) and by means of clamping means (5, 6) clamped to one another and/or to the work-table during the welding. A rotating welding means (12, 13) is arranged to move along a joint between the work pieces while being pressed against said workpieces during the welding. Additional heat is supplied to the joint prior to and/or during the welding operation, in excess of the frictional heat generated in the joint from the rotation of the welding means and of any other heat hat may be supplied to the joint in any other manner by the welding means.
    Type: Grant
    Filed: April 3, 1998
    Date of Patent: December 19, 2006
    Assignee: ESAB AB
    Inventors: Karl-Erik Knipström, Anders Malm
  • Patent number: 7149601
    Abstract: In a friction agitation processing for processing a workpiece by penetrating a rotating processing tool into the workpiece keeping rotation, upon an occurrence of an emergency in execution of friction agitation processing, the processing tool is removed from the workpiece after a finishing time of scheduled friction agitation processing and thereafter stopped in rotation, so as thereby to prevent the processing tool from being locked in the workpiece.
    Type: Grant
    Filed: October 31, 2003
    Date of Patent: December 12, 2006
    Assignee: Mazda Motor Corporation
    Inventor: Kotoyoshi Murakami
  • Patent number: 7137545
    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.
    Type: Grant
    Filed: January 14, 2004
    Date of Patent: November 21, 2006
    Assignee: Honda Motor Co., Ltd.
    Inventors: Masaru Odajima, Hideo Nakamura
  • Patent number: 7124929
    Abstract: A probe for friction stir welding MMCs, ferrous alloys, non-ferrous alloys, and superalloys, as well as non-ferrous alloys, the probe including a shank, a shoulder, and a pin disposed through the shoulder and into the shank, wherein the pin and the shoulder at least include a coating comprised of a superabrasive material, the pin and shoulder being designed to reduce stress risers, disposing a collar around a portion of the shoulder and the shank to thereby prevent movement of the shoulder relative to the shank, and incorporating thermal management by providing a thermal flow barrier between the shoulder and the shank, and between the collar and the tool.
    Type: Grant
    Filed: November 10, 2003
    Date of Patent: October 24, 2006
    Assignees: SII MegaDiamond, Inc., Advanced Metal Products, Inc., Brigham Young University
    Inventors: Tracy W. Nelson, Carl D. Sorensen, Scott Packer, Paul Allen Felter
  • Patent number: 7121450
    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.
    Type: Grant
    Filed: March 4, 2004
    Date of Patent: October 17, 2006
    Assignee: Hitachi, Ltd.
    Inventors: Masakuni Ezumi, Masaaki Shigeyama, Tetsuya Matsunaga
  • Patent number: 7121448
    Abstract: The present invention provides a friction stir welding apparatus and associated thermal management systems and methods for joining one or more similar or dissimilar materials forming a workpiece along a joint to be welded. The friction stir welding apparatus includes a pin tool apparatus selectively disposed adjacent to and in direct contact with a first surface of the workpiece along the joint to be welded and a heating member disposed adjacent to a second surface of the workpiece along the joint to be welded, the heating member operable for controllably heating at least a portion of the workpiece adjacent to the joint to be welded. The friction stir welding apparatus also includes an annular spindle having an interior portion and an axis, the interior portion of the annular spindle at least partially defining one or more cooling channels, the one or more cooling channels operable for containing a cooling fluid.
    Type: Grant
    Filed: August 29, 2003
    Date of Patent: October 17, 2006
    Assignee: General Electric Company
    Inventors: Pazhayannur Ramanathan Subramanian, Earl Claude Helder, Timothy Joseph Trapp, Mark Lawrence Hunt, Timothy V Stotler
  • Patent number: 7097091
    Abstract: Disclosed is a friction stir welding method for welding two members to be welded which differ in physical properties and/or mechanical properties by abutting the two members to each other, inserting a pin portion of a rotary tool having the pin portion and a shoulder portion to the abutment surfaces of the two members, and moving the rotary tool along the abutment surfaces. The pin portion is inserted to only one of the members, the pin portion is not inserted to the other of the members but only the shoulder portion is set in contact with the other of the members, and, while this condition is maintained, the rotary tool is moved. With this method, only the member on the side where the pin is inserted can be made to undergo plastic flow attendant on a friction stir action. The metal in plastic flow is pressed against the opposite member at an elevated temperature and high pressure, whereby diffusion of atoms is caused in the vicinity of the abutment surfaces, and the members are welded.
    Type: Grant
    Filed: July 23, 2002
    Date of Patent: August 29, 2006
    Assignee: Hitachi, Ltd.
    Inventors: Hisanori Okamura, Kinya Aota, Kouji Satou, Masahiko Sakamoto
  • Patent number: 7093745
    Abstract: A body member and flange members are butted together at a first abutment portion and a second abutment portion. The first and second abutment portions are held by first and second backing jigs, respectively. The first backing jig has a circumscribing recessed section corresponding to an inner circumferential surface of the first abutment portion. Further, the first backing jig has a circumscribing opening communicated with the bottom of the recessed section. On the other hand, the second backing jig has a circumscribing recessed section corresponding to an inner circumferential surface of the second abutment portion. Further, the second backing jig has a circumscribing opening communicated with the bottom of the recessed section. First and second buffer members are attached to the recessed sections, respectively.
    Type: Grant
    Filed: January 14, 2004
    Date of Patent: August 22, 2006
    Assignee: Honda Motor Co., Ltd.
    Inventors: Hideo Nakamura, Tokiyuki Wakayama, Noriaki Ishii, Tutomu Asaina, Masaru Odajima, Masahiko Natsuume
  • Patent number: 7083076
    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.
    Type: Grant
    Filed: July 7, 2004
    Date of Patent: August 1, 2006
    Assignee: The Boeing Company
    Inventor: Kevin T. Slattery
  • Patent number: 7080438
    Abstract: While at least one of first and second tools 4 and 5 of a junction tool 6 is rotated, a workpiece W made of a plurality of plate materials W1 and W2 superimposed in their thickness directions is nipped between the first and second tools and joined at points. The first tool 4 is provided with a pin 44 protruding from its distal end surface 43 along a junction axis X. The second tool 5 is provided with a depression 51 which is depressed at its distal end surface 53 along the junction axis X. By the first pin 44 of the first tool 4 and the depression 51 of the second tool 5, the superimposed surface W3 of the softened workpiece W is caulked in the direction of the junction axis X. Further, plastic flow is generated within the workpiece W so as to agitate the vicinity of the superimposed surface W3.
    Type: Grant
    Filed: July 22, 2003
    Date of Patent: July 25, 2006
    Assignee: Mazda Motor Corporation
    Inventor: Kotoyoshi Murakami
  • Patent number: 7073701
    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.
    Type: Grant
    Filed: June 23, 2003
    Date of Patent: July 11, 2006
    Assignee: Hitachi, Ltd.
    Inventors: Kinya Aota, Tsuyoshi Takenaka, Yasuo Ishimaru
  • Patent number: 7055732
    Abstract: We have discovered a method of producing a complex-shaped aluminum alloy article, where welding has been employed to form the article, where an anodized aluminum coating is produced over a surface of the article including the weld joint, and where the anodized aluminum coating is uniform, providing improved performance over that previously known in the art for welded articles exposed to a corrosive plasma environment.
    Type: Grant
    Filed: August 28, 2003
    Date of Patent: June 6, 2006
    Assignee: Applied Materials, Inc.
    Inventors: Senh Thach, Jennifer Y. Sun, Shun Jackson Wu, Yixing Lin, Clifford C. Stow
  • Patent number: 7056594
    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.
    Type: Grant
    Filed: June 23, 2003
    Date of Patent: June 6, 2006
    Assignee: Hitachi, Ltd.
    Inventors: Kinya Aota, Tsuyoshi Takenaka, Yasuo Ishimaru
  • Patent number: 7051916
    Abstract: The end of a hollow member 10 is abutted against the end of a hollow member 20. The end of a face plate 21 is supported on a protrusion 15. A small-diameter portion 52 of a rotary tool 50 is inserted into the abutted area, and the tool 50 is moved along the abutted region while being rotated in a clockwise direction as observed from the large-diameter potion 51. Thus, the pressure of mobilized metal is greater on the right side of the axial center of the rotary tool. The thickness of the member from the tip of the inserted small-diameter portion 51 to the hollow areas 10b and 10a is thicker at the right side where the pressure is higher, thus preventing metal from flowing out into the hollow region 10a.
    Type: Grant
    Filed: August 15, 2002
    Date of Patent: May 30, 2006
    Assignee: Hitachi, Ltd.
    Inventors: Masakuni Ezumi, Kazushige Fukuyori, Akihiro Satou
  • Patent number: 7048175
    Abstract: Expanded structural assemblies and preforms and methods therefor are provided. Each preform can include at least two structural members in a stacked relationship, defining cells that can be inflated to expand the preform. Elongate members can be disposed between the structural members along the cells to define passages through which fluid can be received during expanding. Further, the structural members of the preform can be connected by friction stir weld joints, some of which can extend only partially through the preform so that the preform defines cells that can be expanded. More than one adjacent friction stir weld joint can be disposed between adjacent cells of the preform to define multiple-pass friction stir weld joints.
    Type: Grant
    Filed: February 18, 2004
    Date of Patent: May 23, 2006
    Assignee: The Boeing Company
    Inventor: Max R. Runyan
  • Patent number: 7036708
    Abstract: In a friction stir welding method of manufacturing a piston for a variable capacity swash plate type compressor, the welder is shifted from the welded portions to a predetermined position while maintaining contact between the welder and one of the piston members. After finishing the friction stir welding, a hole is not formed in the welded portions of the piston members to improve durability of the welded portions. The piston members are elastically supported by support rollers to align the central axial lines of the piston members with the axial line of the chuck, even though the diameters of the piston members differ.
    Type: Grant
    Filed: September 9, 2003
    Date of Patent: May 2, 2006
    Assignee: Halla Climate Control Corporation
    Inventors: Dao-Kyu Park, Kyoung-Duck Kim
  • Patent number: 7036707
    Abstract: Disclosed is a friction stir welding technique which avoids occurrence of a dent, in a joining region, extending to a level beneath the joined surfaces. At end portions of the frame members to be joined, at the joining region, thickened parts which project toward the rotary body joining tool are provided. Two adjoining thickened parts, of adjacent members to be joined, can form a trapezoid shape. The rotary body joining tool has a small-diameter tip portion and a larger diameter portion. The rotary body joining tool is inserted in the thickened parts. In a state where the rotary body joining tool has been inserted small-diameter tip end first, to a level where the larger diameter portion of the rotary body joining tool overlaps the thickened part but does not extend below the upper surface of the non-thickened surfaces of the members joined, the rotary body is rotated and moved along the joining region. Even when a gap exists between two thickened parts, a desirable joining can be carried out.
    Type: Grant
    Filed: July 2, 2003
    Date of Patent: May 2, 2006
    Assignee: Hitachi, Ltd.
    Inventors: Kinya Aota, Masakuni Ezumi, Yasuo Ishimaru, Hisanori Okamura, Isao Funyuu, Akihiro Satou
  • Patent number: 7032801
    Abstract: A friction welding tool for friction welding can be controlled with respect to measuring accuracy based upon the temperature in the weld zone. This is attained by determining the temperature values of the weld zone by way of a temperature sensor, which is arranged with its measuring point in the pin of the stir welding tool.
    Type: Grant
    Filed: August 2, 2002
    Date of Patent: April 25, 2006
    Assignee: EADS Deutschland GmbH
    Inventors: Klaus Raether, Juergen Silvanus, Werner Zimmermann
  • Patent number: 7032800
    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 a tungsten-based refractory material. 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.
    Type: Grant
    Filed: May 30, 2003
    Date of Patent: April 25, 2006
    Assignee: General Electric Company
    Inventors: Pazhayannur Ramanathan Subramanian, Bernard Patrick Bewlay, Earl Claude Helder, Timothy Joseph Trapp
  • Patent number: 7017792
    Abstract: A machining method for an integrated piping plate, for example, composed of a plurality of plates joined together, and in which an instrument and a component constituting an apparatus, or the instrument, or the component are or is disposed on one surface or both surfaces of the integrated piping plate, and the instrument and the component, or the instrument, or the component are or is connected by fluid channel grooves formed in joining surfaces of the plates, and communication holes formed in the plates. The machining method welds the joining surfaces of the plates around the entire periphery of the fluid channel grooves, for example, by an FSW welding machine, to join the plates. Compared with joining of the plates by an adhesive, the machining method can increase the durability of the plate joining portion and increase pressure resistance. Also, the method can increase work efficiency and further downsize the integrated piping plate.
    Type: Grant
    Filed: January 29, 2002
    Date of Patent: March 28, 2006
    Assignee: Mitsubishi Heavy Industries, Ltd.
    Inventors: Haretaro Hidaka, Michio Tsukamoto
  • Patent number: 7000303
    Abstract: A method of repairing a crack (14) in a component (12). The method includes preparing a surrounding surface (22) of the crack (14) for repair and welding a first portion (24) of the component (12) on a first side (26) of the crack (14) to a second portion (28) of the component (12) on a second side (30) of the crack (14) to form a fused crack area (50). The method may also include applying a patch (78) over the fused crack area (50) for additional strength.
    Type: Grant
    Filed: October 24, 2002
    Date of Patent: February 21, 2006
    Assignee: The Boeing Company
    Inventors: Rajesh Talwar, Rigoberto Perez
  • Patent number: 6997369
    Abstract: Two members 11 and 12 are butted against each other, and the butted portion is cut with a cutter 20 to form a slit 14 thereto, and a filler member 21 is inserted to slit 14 using rollers 22, 23 and 25. Then, friction stir welding is performed to weld filler member 21 and two member 11 and 12 disposed on both sides thereof using a rotary tool 35, and the position of a gap formed between an end of filler member 21 at the upstream side in the rotating direction of rotary tool 35 and one member 11b at the upstream side in the rotating direction is detected using an optical sensor 35. Then, half the width of filler member 21 is added to the detected position, and the calculated position is set as the position of the rotary tool 35.
    Type: Grant
    Filed: January 23, 2004
    Date of Patent: February 14, 2006
    Assignee: Hitachi, Ltd.
    Inventors: Koji Hamada, Ryoji Ishida, Masakuni Ezumi
  • Patent number: 6991149
    Abstract: Two beams 17 and 18 perpendicular to a moving trajectory Q are formed in an intake port opening 14 of a cylinder head material to serve as margins for interfering with deformation of the opening 14 due to softening of the material, thereby a deformation of the material and a void caused by the deformation can be prevented in the frictional stirring with the rotary tool.
    Type: Grant
    Filed: July 26, 2002
    Date of Patent: January 31, 2006
    Assignee: Mazda Motor Corporation
    Inventors: Hiroaki Kusunoki, Tsutomu Masuda, Koji Tomiya
  • Patent number: 6986452
    Abstract: The present invention provides an improved method and apparatus for joining aluminum allow panels (eg. 2090-T83 aluminum lithium alloy). The method preliminarily positions two panels and skin panels next to each other so that a stringer panel overlaps a skin panel. A friction stir weld pin tool penetrates through one panel and at least partially into another panel. The panel material around the pin tool is frictionally heated, plasticized and joined until the faying surface is substantially consumed. In another embodiment, a tee-shaped structure is formed using friction stir welding to join three panels together. A projecting part of one panel (center, vertical) provides material that becomes a contoured corner panel below two side, horizontal panels after friction stir welding is completed (FIGS.
    Type: Grant
    Filed: May 15, 2003
    Date of Patent: January 17, 2006
    Assignee: Lockheed Martin Corporation
    Inventors: Brian J. Dracup, William J. Arbegast
  • Patent number: 6983873
    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.
    Type: Grant
    Filed: June 23, 2003
    Date of Patent: January 10, 2006
    Assignee: Hitachi, Ltd.
    Inventors: Kinya Aota, Tsuyoshi Takenaka, Yasuo Ishimaru
  • Patent number: 6978923
    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.
    Type: Grant
    Filed: June 23, 2003
    Date of Patent: December 27, 2005
    Assignee: Hitachi, Ltd.
    Inventors: Kinya Aota, Tsuyoshi Takenaka, Yasuo Ishimaru
  • Patent number: 6966481
    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.
    Type: Grant
    Filed: June 23, 2003
    Date of Patent: November 22, 2005
    Assignee: Hitachi, Ltd.
    Inventors: Kinya Aota, Tsuyoshi Takenaka, Yasuo Ishimaru
  • Patent number: 6955283
    Abstract: There is provided a mandrel for spin forming that has a backing plate with removably attached mandrel portions and mandrel spacers, such that the mandrel is adaptable to numerous configurations. The various configurations of the mandrel are used to provide different spin forming contour surfaces upon which metal sheets or other spin formable materials can be spin formed. The adaptable mandrel also provides the ability to create a desired spin formed product from either a single metal sheet or multiple metal sheets joined by friction stir welding or other suitable processes. A spin formed welded metal sheet may also undergo a trimming process to remove the portions of the welded metal sheet having sufficiently different material properties resulting from the weld process, including the weld joint.
    Type: Grant
    Filed: September 8, 2003
    Date of Patent: October 18, 2005
    Assignee: The Boeing Company
    Inventors: Ronnie G. Kendall, Dwight A. Burford
  • Patent number: 6953144
    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.
    Type: Grant
    Filed: June 23, 2003
    Date of Patent: October 11, 2005
    Assignee: Hitachi, Ltd.
    Inventors: Kinya Aota, Tsuyoshi Takenaka, Yasuo Ishimaru
  • Patent number: 6953140
    Abstract: A friction stir welding apparatus of a piston for variable capacity swash plate type compressor bonds two pistons through frictions stir welding without forming a hole in welded portions of the piston members. The friction stir welding apparatus includes: A support that rotatably supports coaxially coupled first and second pistons. A welder, rotatably inserted into welded portions of the first and second pistons supported on the support, performs friction stir welding along the rotation direction of the first and second pistons. Support rollers elastically mounted on the lower portions of the pistons have central axis lines of the piston members on central axis lines of the rotation support while the pistons are supported on the support. The rollers vertically move through a predetermined height while supporting the pistons. The welder is transferred from the welded portions to another position after welding of the welded portions.
    Type: Grant
    Filed: September 9, 2003
    Date of Patent: October 11, 2005
    Assignee: Halla Climate Control Corporation
    Inventors: Dae-Kyu Park, Kyoung-Duck Kim
  • Patent number: 6936332
    Abstract: The friction stir welding technique disclosed avoids occurrence of a dent in adjoining region extending to a level beneath the joined surfaces. At end portions of the frame members to be joined, thickened parts, which project toward the rotary body joining tool, are provided. The Two adjoining thickened parts form a trapezoid shape. The rotary body joining tool has a small-diameter tip portion and a larger diameter portion, and is inserted in the thickened parts. When the rotary body joining tool has been inserted small-diameter tip end first to a level where the larger diameter portion of the rotary body joining tool overlaps the thickened part, the rotary body is rotated and moved along the joining region. Even when a gap exists between two thickened parts, a desirable joining can be carried out. After the joining, the remaining parts of the thickened parts can be machined to form a smooth surface.
    Type: Grant
    Filed: April 10, 2001
    Date of Patent: August 30, 2005
    Assignee: Hitachi, Ltd.
    Inventors: Kinya Aota, Masakuni Ezumi, Yasuo Ishimaru, Hisanori Okamura, Isao Funyuu, Akihiro Satou
  • Patent number: 6923362
    Abstract: An internal channel in a metal body for use in applications where internal fluid flow within a metal body is desired, as in a heat exchanger. The internal channel is formed in the metal body by frictionally stirring with a pin plunged into the metal body, and traversing the metal body with the pin.
    Type: Grant
    Filed: September 30, 2002
    Date of Patent: August 2, 2005
    Assignee: The Curators of University of Missouri
    Inventor: Rajiv S. Mishra
  • Patent number: 6921012
    Abstract: To vibration weld two components (1, 2), which are to be joined together on a welding surface (8), a vibrational movement (7) is transmitted from a tool (3) to the vibrating component (1) while the other component (2) is fixed. During the procedure, the tool (3) presses the vibrating component (1) onto the fixed component (2) in a direction (9) substantially perpendicular to the vibrational movement (7). To avoid the need for a structured surface on the tool (3) in order to transmit the vibrational movement to the vibrating component, which structured surface could leave marks on the vibrating component, the vibrating component (1) has at least one relief-like depression (5) or elevation (6), which transmits the vibrational movement from the tool (3) to the vibrating component (1).
    Type: Grant
    Filed: March 18, 2003
    Date of Patent: July 26, 2005
    Assignee: Mann & Hummel GmbH
    Inventors: Thomas Jessberger, Matthias Mueller
  • Patent number: 6921010
    Abstract: Method of joining together two planar members, by a friction stir welding operation wherein a rotary tool having a probe is moved relative to a joint region defined between the mutually butted planar members such that the probe is rotated and inserted in the joint region. The welding operation is performed by using a tab plate having a cutout formed in its end face such that the cutout has a width not smaller than a radius of a peripheral circle to be described by the shoulder surface, and a depth not smaller than a minimum radius of the probe and not larger than the radius of the peripheral circle.
    Type: Grant
    Filed: October 27, 2003
    Date of Patent: July 26, 2005
    Assignee: Sumitomo Light Metal Industries, Ltd.
    Inventors: Sunao Tanaka, Masaki Kumagai
  • Patent number: 6915939
    Abstract: A friction agitation joining tool (10A, 10B) includes a rotor (11) having an end portion to be pressed onto at least one of surfaces of joining members (11a, 1b) and a probe (13) to be inserted into a joining portion (3) of the joining-members (1a, 1b), wherein the probe (13) has a diameter smaller than a diameter of the rotor (11). An end face (12) of the end portion of the rotor (11) is formed into a concave surface dented from a periphery of the end face (12) toward a rotational center of the end face (12). The probe (13) is protruded from the rotational center of the end face (12). The end face (12) is provided with a spiral groove (15) or an annular groove (16) surrounding the probe (13). By performing the joining operation with the joining tool (10A, 10B), a joined member with a good joint can be obtained.
    Type: Grant
    Filed: September 20, 2001
    Date of Patent: July 12, 2005
    Assignee: Showa Denko K.K.
    Inventors: Takenori Hashimoto, Shigetoshi Jhogan, Yoshitaka Nagano
  • Patent number: 6915938
    Abstract: A damper for reducing vibration in a least a portion of a component during inertia welding. The damper includes a generally annular body having a spiral slot formed therein.
    Type: Grant
    Filed: December 4, 2002
    Date of Patent: July 12, 2005
    Assignee: General Electric Company
    Inventors: Charles William Carrier, Steven A. Ross, Robert R. Kursmark, Chris League, John Absi
  • Patent number: 6913186
    Abstract: An apparatus and method for forming a friction stir weld joint in a workpiece are provided. The apparatus includes a friction stir welding tool having a shoulder and a rotatable pin extending therefrom. The rotational speed of the pin can be adjusted during a friction stir welding operation, e.g., cyclically and/or according to a predetermined schedule, so that the pin mixes the plasticized material of the workpiece. The workpiece can also be preheated before friction stir welding.
    Type: Grant
    Filed: September 11, 2003
    Date of Patent: July 5, 2005
    Assignee: The Boeing Company
    Inventor: Amitabh Vyas
  • Patent number: 6910616
    Abstract: A method of constructing a preform for use in forming a machined structural assembly is provided. The method includes determining the dimensions of the machined structural assembly. First and second structural members are selected based on the predetermined dimensions of the machined structural assembly. The first structural member is positioned adjacent the second structural member so as to define at least two contact surfaces. The contact surfaces of the first and second structural members are friction welded to construct the preform such that the preform has dimensions approximating the dimensions of the machined structural assembly to thereby reduce material waste when forming the machined structural assembly. A machined structural assembly having predetermined dimensions is formed from the preform by machining away excess material.
    Type: Grant
    Filed: March 7, 2002
    Date of Patent: June 28, 2005
    Assignee: The Boeing Company
    Inventors: Jeremiah E. Halley, Kevin T. Slattery
  • Patent number: 6905060
    Abstract: A sealant for a weld joint and an associated weld joint and method are provided. The sealant includes aluminum and germanium and is characterized by a melting temperature that is lower than the melting temperature of the structural member that is joined. The sealant, which is disposed between faying surfaces of the structural members, can fill the spaces between the structural members to prevent the entry of chemicals, moisture, debris, and other substances, thereby reducing the likelihood of corrosion of the joint or structural members at the interface. Further, the sealant can be diffusion bonded to the faying surfaces, for example, by the heat generated during the joining process.
    Type: Grant
    Filed: October 24, 2003
    Date of Patent: June 14, 2005
    Assignees: The Boeing Company, The Curators of the University of Missouri
    Inventors: David C. Van Aken, John A. Baumann, Richard J. Lederich, Rajesh Talwar
  • Patent number: 6896169
    Abstract: A tool for forming a friction stir weld joint in a workpiece is provided. 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. In particular, the stirring portion of the pin defines at least one groove and ridge, each of which extend generally circumferentially around an axis of the pin. The tool can also include a second shoulder opposing the first shoulder such that the pin extends therebetween.
    Type: Grant
    Filed: August 29, 2003
    Date of Patent: May 24, 2005
    Assignee: The Boeing Company
    Inventor: George D. Hempstead
  • Patent number: 6892924
    Abstract: A friction stir rivet is rotated in a precessing motion and driven through a first fusible workpiece into an engaged second fusible workpiece, causing local portions of the first and second workpieces to plasticize. When the rivet is driven through the first workpiece and into the second workpiece, rotation is stopped and the plasticized material solidifies around the rivet creating an enlarged weld joining the metal workpiece and encompassing the rivet, which provides additional mechanical strength.
    Type: Grant
    Filed: December 18, 2002
    Date of Patent: May 17, 2005
    Assignee: General Motors Corporation
    Inventors: Robin Stevenson, Pei-Chung Wang
  • Patent number: 6886732
    Abstract: A machining device comprising five axial kinetic coordinate systems that can be controlled simultaneously, three axes of which, are linear moving axes and two axes of which are rotary axes, with one axis of the five axes being provided with a tool rotating function, whereby said machining device is equipped with a cutting tool 51 and a friction stir welding tool 52. The current value observed when a large-diameter portion of said tool 52 contacts the work object is set in advance, and by observing the torque current of the rotary shaft of the tool 52 during friction stir welding, the insertion depth of the tool 52 can be controlled by maintaining the observed torque current above the preset current value, thus providing a good weld. A single device can provide both the cutting and the welding. Thus, it is possible to reduce equipment cost, installation space, plant area, lead time and production cost.
    Type: Grant
    Filed: August 27, 2002
    Date of Patent: May 3, 2005
    Assignee: Hitachi, Ltd.
    Inventor: Fumio Yoshinaga
  • Patent number: 6880743
    Abstract: The average strength of a pull plug weld is increased and weak bonding eliminated by providing a dual included angle at the top one third of the pull plug. Plugs using the included angle of the present invention had consistent high strength, no weak bonds and were substantially defect free. The dual angle of the pull plug body increases the heat and pressure of the weld in the region of the top one third of the plug. This allows the plug to form a tight high quality solid state bond. The dual angle was found to be successful in elimination of defects on both small and large plugs.
    Type: Grant
    Filed: October 8, 2002
    Date of Patent: April 19, 2005
    Assignee: Lockheed Martin Corporation
    Inventors: Edmond R. Coletta, Mark A. Cantrell
  • Patent number: 6877210
    Abstract: A method of making a squirrel cage rotor of copper material for use in AC or DC motors, includes forming a core with longitudinal slots, inserting bars of conductive material in the slots, with ends extending out of opposite ends of the core, and joining the end rings to the bars, wherein the conductive material of either the end rings or the bars is copper. Various methods of joining the end rings to the bars are disclosed including electrofriction welding, current pulse welding and brazing, transient liquid phase joining and casting. Pressure is also applied to the end rings to improve contact and reduce areas of small or uneven contact between the bar ends and the end rings. Rotors made with such methods are also disclosed.
    Type: Grant
    Filed: January 16, 2003
    Date of Patent: April 12, 2005
    Assignee: UT-Battelle, LLC
    Inventor: John S. Hsu
  • Patent number: 6874672
    Abstract: In a frictional stirring weld apparatus for bonding elements with a rotary tool, a head is movable with respect to the elements to position and orient the rotary tool so that a pin of the rotary tool is aligned along a boundary between first surfaces and a shoulder of the rotary tool faces to second surfaces extending radially outward from the first surfaces, and to generate a relative movement between the rotary tool and the elements along the second surfaces, and a compensating member is capable of holding thereon the rotary tool, at least partially rotatable on the rotational axis with respect to the head to rotate the rotary tool, and supported on the head movably along the rotational axis with respect to the head so that a positional relationship between the rotary tool and a combination of the elements is adjustable in a direction parallel to the rotational axis.
    Type: Grant
    Filed: February 25, 2003
    Date of Patent: April 5, 2005
    Assignee: Hitachi, Ltd.
    Inventors: Kazutaka Okamoto, Satoshi Hirano, Masahisa Inagaki, Tomio Odakura