Abstract: A welding head assembly has a work piece disposed between its containment plates' opposing surfaces with the work piece being maintained in a plastic state thereof at least in a vicinity of the welding head assembly's stir rod as the rod is rotated about its longitudinal axis. The welding head assembly and the work piece experience relative movement therebetween in a direction perpendicular to the rod's longitudinal axis as the work piece is subjected to a compressive force applied by the containment plates. A first source coupled to the first containment plate applies a first ultrasonic wave thereto such that the first ultrasonic wave propagates parallel to the direction of relative movement. A second source coupled to the second containment plate applies a second ultrasonic wave thereto such that the second ultrasonic wave propagates parallel to the direction of relative movement.

Abstract: Disclosed is a friction stir welding tool (10) equipped with a probe (13) and a holder (16). At the tip of the probe (13) there is a pin part (11) and at the base there are probe-side protrusions (24) and probe-side recesses (25). At the tip of the holder (16) there are holder-side recesses (27) which mate with the probe-side protrusions (24), and holder-side protrusions (28) which mate with the probe-side recesses (25). External force applied to the probe (13) is transmitted from the probe-side protrusions (24) to the holder-side recesses (27) and from the probe-side recesses (25) to the holder-side protrusions (28).

Abstract: An apparatus for friction stir welding includes a rotatably drivable pin having a drive end and a free end; a cylindrical engaging portion provided between the drive end and the free end and including a circumferential surface for engagement with one or more workpieces; and first and second shoulder elements arranged concentrically around the pin and positioned on respective sides of the of the engaging portion adjacent the drive end and the free end, respectively. The first and second shoulder elements include respective first and second bearing surfaces facing the engaging portion and extending perpendicularly to the axis of rotation. The mechanical and thermal loading of the pin and the thermal loading of the workpieces are reduced by merit of the second shoulder element being connected to the pin so as to be freely rotatable about the axis of rotation.

Abstract: A low-temperature friction-based coating method termed friction stir fabrication (FSF) is disclosed, in which material is deposited onto a substrate and subsequently stirred into the substrate using friction stir processing to homogenize and refine the microstructure. This solid-state process is capable of depositing coatings, including nanocrystalline aluminum and/or metal matrix composites and the like, onto substrates such as aluminum at relatively low temperatures. A method of making rod stock for use in the FSF process is also disclosed.

Abstract: The linear friction welding (LFW) apparatus of this invention, in various embodiments includes a vibrating assembly or assemblies, which simultaneously vibrates both work pieces along the weld axis during the weld process. In one embodiment, separate vibrating assemblies are used to vibrate each work piece along the weld axis relative to each other. Each vibrating assembly has its own oscillator mechanism with motors and cams that can be moved into and out of phase with that of the other vibrating mechanism to generate the relative movement between the work pieces. In another embodiment, the apparatus includes a vibrating assembly that uses a single oscillator and two sets of rocker arms supporting carriages operatively connected by a linkage mechanism to simultaneously vibrate both work pieces along the weld axis.

Abstract: A method of welding including forming a filler material of a first oxide dispersoid metal, the first oxide dispersoid material having first strengthening particles that compensate for decreases in weld strength of friction stir welded oxide dispersoid metals; positioning the filler material between a first metal structure and a second metal structure each being comprised of at least a second oxide dispersoid metal; and friction welding the filler material, the first metal structure and the second metal structure to provide a weld.

Abstract: A welding tool for joining at least two workpieces at a joining region by friction stir welding includes a tool pin arranged along one axis of the welding tool, for applying frictional heat to the workpieces. The welding tool also includes a shoulder surrounding the tool pin, for separating the joining region from the surrounding area. The shoulder is moveable essentially parallel to the axis of the welding tool.

Abstract: The linear friction welding apparatus of this invention includes two vibrating assemblies, which simultaneously vibrate both work pieces along different weld axis within the plane of the weld interface during the weld process. The LFW apparatus allows one or both work pieces to be independently vibrated against one another along different weld axis to control and concentrate the application of thermal energy across the weld surfaces caused by friction in certain areas of the weld surface and certain times during the weld process.

Abstract: A linear friction welding method and linear friction welding apparatus for joining two work pieces. The method involves vibrating a third weld component, or “coupon” between the two principle work pieces under a welding pressure. Friction between the coupon and work pieces causes the material at the weld surfaces to plasticize. Abruptly halting the vibration and pressing the work pieces against the coupon under a final load or forging pressure sets the weld interface.

Abstract: The apparatus and method allows multiple components to be simultaneously bonded to a central shaft or tube using linear friction welding in a single welding process. The method involves simultaneously pressing the work pieces radially against the central shaft or tube at the desired locations while the shaft is vibrated axially. The weld is facilitated by the use of a linear friction welding machine, which includes a number of fixtures and press assemblies to hold and press the various work pieces against the central shaft or tube and a vibrating assembly for vibrating the central shaft or tube.

Abstract: In a friction stir welding apparatus, workpiece fixing surface plates (3a, 3b) are installed on a framework (1). In addition, a welding apparatus main body (8) including a bobbin tool (5) having a probe (5a) protruding upward from a gap (4), a spindle (6) configured to attach the bobbin tool (5) to an upper end section thereof, and a spindle driving apparatus (7) configured to pivot the spindle (6) is movably installed at the framework (1) in a longitudinal direction of the gap (4) via linear guide mechanisms (9) installed at both sides of the welding apparatus main body (8). Further, a moving apparatus (10) is installed to move the welding apparatus main body (8) in the longitudinal direction of the gap (4). According to the friction stir welding apparatus, since the welding apparatus main body (8) is supported by the framework (1) via both of the linear guide mechanisms (9), a large welding reaction force can be sufficiently received.

Abstract: The present invention relates to tools and methods for disposing, coating, repairing, or otherwise modifying the surface of a metal substrate using frictional heating and compressive/shear loading of a consumable metal against the substrate. Embodiments of the invention include friction-based fabrication tooling comprising a non-consumable member with a throat and a consumable member disposed in the throat, wherein consumable filler material is capable of being introduced to the throat in a continuous manner during deposition using frictional heating and compressive/shear loading of the filler material onto the substrate. Preferred embodiments according to the invention include such tools operably configured for applying a force or displacement to the filler material during deposition.

Abstract: An apparatus for use in a friction stir operation, such as friction stir welding (FSW) or friction stir processing (FSP). The apparatus may have a rotating tool adapted to be plunged into a material, where the material is susceptible to being softened by heating. The rotating tool may further be adapted to be advanced along a surface of the material. An optical energy generating subsystem may be used to heat a portion of the material using optical energy as the tool is advanced along the material.

Abstract: A friction stir welding tool for welding of metallic plates and especially steel plates. The friction stir welding tool is made of cemented carbide comprising WC grains in a binder phase and wherein the welding tool is at least partly coated with a surface coating comprising Al2O3.

Abstract: The tool for friction stir welding is a tool adapted to operatively engage a tube and a tubesheet to form a sealed joint. The tool has two components. The first component is a shoulder having orthogonal faces for simultaneously engaging the sheet and the tube, the shoulder defining a bore terminating in an aperture at the junction of the faces. The second component is a stir welding probe that is insertable into the bore and has an end exiting the aperture at the end of the bore. A forging pressure urges the shoulder against the junction of the tube and tubesheet. The probe is rotated about its axis, penetrating the tube and tubesheet and generating heat through friction to weld the tube to the tubesheet, while the shoulder is rotated about the tube so that the weld forms a seal about the circumference of the tube.

Abstract: A friction stir processing tool is formed from a Ni-based dual multi-phase intermetallic compound alloy containing rhenium(Re). The Ni-based dual multi-phase intermetallic compound alloy is preferably formed by casting, while gradually cooling, a melt containing all the components of the composition and is preferably heat treated after casting. Moreover, in a method for friction stir processing, a work is softened by friction heat generated when the friction stir processing tool, while rotating, is pressed against the work to be processed. The friction stir processing tool includes the Ni-based dual multi-phase intermetallic compound alloy, and therefore further high hardness is exhibited to improve abrasion resistance, so that even a long period of friction stir processing can be endured.

Abstract: The invention relates to a friction application device having an application element which is movable by means of a moving device on a surface of a workpiece and in a relative movement with respect to the surface of the workpiece, wherein at least one supporting tool which is in contact with the application element and prevents bead formation on the application element is arranged in the contact region between the application element and the surface of the workpiece.

Abstract: A friction stir welding tool includes that a body and a pin formed integrally with the body at one end thereof. The body and pin further include a first material and a second material; wherein the first material further includes a molybdenum-based refractory alloy; and wherein the second material further includes hafnium, lanthanum, carbon, titanium, zirconium, or combinations thereof.

Abstract: Friction Stir Welding (FSW) devices and methods for simultaneously welding both sides of an arcuate joint are described. The FSW method includes the step of operating a FSW tool and an anvil on the exterior surface of the joint and simultaneously operating another FSW tool and anvil on the interior surface of the joint. The anvils are positioned in a juxtaposing manner to the FSW tools, and move in tandem with the FSW tools, thus providing a supporting force to the FSW tools during their operation.

Abstract: Disclosed herein is a method of making a structure by ultrasonic welding and superplastic forming. The method comprises assembling a plurality of workpieces comprising a first workpiece including a first material having superplastic characteristics; ultrasonically welding the first workpiece to a second workpiece, to form an assembly; heating the assembly to a temperature at which the first material having superplastic characteristics is capable of superplastic deformation, and injecting a fluid between the first workpiece and the second workpiece to form a cavity between the first workpiece and the second workpiece.

Abstract: Disclosed is a friction-stir joining method for joining a first member, having a base metal covered with a substance different from the base metal, with a second member with the second member placed on the first member by moving a joining tool along a joining line having thereon a joining start point and a joining finish point. The method includes steps of: inserting the joining tool into the second member at the joining start point; moving the joining tool a predetermined distance along the joining line in a direction opposite the joining finish point; causing the joining tool to turn back at a turning-back point spaced the predetermined distance from the joining start point; moving the joining tool along the joining line to the joining finish point past the joining start point; and pulling the joining tool out from the second member at the joining finish point.

Abstract: A system and method for friction stir welding of small diameter tubing, wherein the small diameter tubing is held in a correct position with a grasp sufficient to perform FSW when the tubing is comprised of high melting temperature materials, wherein the small diameter tubing can be rotated by the positioning and holding system while a FSW tool is held stationary, or vice versa, wherein internal mandrels are also described which can fit inside the smaller dimensions of the small diameter tubing and expand to provide a counter force to prevent deformation of the tubing when forces are applied by the FSW tool, wherein new FSW tool geometries are also described which enable the FSW tool to direct more heat on a tool/workpiece interface to counteract a lack of contact between the FSW shoulder and the workpiece because of tube curvature, and wherein the FSW tool is positioned on a small diameter tube by trailing the joint to provide desirable heating at the joint/workpiece interface and surface finishing.

Abstract: There is provided a tool for friction stir welding having excellent wear resistance and chipping resistance. The tool for friction stir welding according to the present invention is a tool for friction stir welding used in friction stir welding processing, wherein the tool for friction stir welding includes a base material, the base material includes a first hard phase and a binder phase, and has a thermal conductivity of 45 W/m·K or less, the first hard phase is formed by WC particles, and the binder phase is formed by an iron group metal and is included in the base material at a volume ratio of 8% by volume or more and 28% by volume or less.

Abstract: Devices and methods for friction stir welding using an anvil with a sacrificial material are disclosed. The method involves the steps of providing an anvil with a sacrificial material on the backside of the workpieces and operating a friction stir welding device to form a weld that joins the workpieces together with the sacrificial material. The anvil comprises a non-sacrificial base portion removably coupled with a sacrificial material.

Abstract: The present invention provides an economic rotation tool for joining a pair of metal members which form an inner corner by abutting the pair of metal members (1) each other, and a joining inner corner method using the same. The rotation tool for joining the pair of metal members which form an inner corner (1) by abutting the pair of metal members each other to perform friction stir welding on an inner corner portion formed by abutting a pair of metal members against each other comprising: a stirring pin (3) to be inserted into the inner corner portion; and a base block (2) supporting the stirring pin (3) and to be brought into contact with one and the other of the pair of metal members respectively, wherein the base block (2) includes: a body portion (4) having a taper shape; and a shoulder portion (5) formed detachably at a tip of the body portion, and the body portion (4) and the shoulder portion (5) are penetrated by the stirring pin (3).

Abstract: A friction stir welding includes a main body for holding a tool and a hot air and cool air separating unit. The separating unit is disposed at the main body and separates a supplied gas into hot air hotter than the gas and cool air cooler than the gas in a tube portion and ejects the cool air from a first end of the tube portion and ejects hot air from a second end of the tube portion. The hot air is supplied to a front side of a movement direction of the tool in the surface of the work piece from a tool side of the friction stir welding apparatus and the cool air is supplied to a rear side of the movement direction of the tool in the surface of the work piece from the tool side of the friction stir welding apparatus.

Abstract: A friction stir welding apparatus includes a rotating tool provided with an upper rotating body arranged to be axially adjustable in position by an upper actuator, a lower rotating body integral with a rotating main rod extending through the upper rotating body and arranged to be axially adjustable in position by a lower actuator, and a stirring part formed in the rod. The upper rotating body and the lower rotating body clamp therebetween a joint of members to be joined placed with their end faces butting each other. The stirring part is rotated to stir the joint by frictional heat to join them. The rotating tool includes a slide plate attached, through a thrust bearing, to one or both of end portions of the upper rotating body and the lower rotating body facing each other to provide good finished surfaces of the joint.

Abstract: A friction stir welding tool of the present invention is used for friction stir welding, and includes: a base material; and a coating layer formed on a surface of at least a portion of the base material that is to be caused to contact workpieces during friction stir welding, the base material being formed of a cemented carbide, and the coating layer containing cubic WC1-x and being formed by electrical discharge machining.

Abstract: A hole in a metal workpiece is filled by friction plug welding. The weld between the workpiece and the plug is reinforced by a weld land in the workpiece that surrounds one end of the plug. The weld land is formed by extruding a portion of the plug into a cavity in an anvil used in the welding process.

Abstract: A method for controlling friction stir welding is provided. The method may include initiating friction stir welding and determining the position of a friction stir welding tool and at least one part being welded. The method may also include adjusting the position of the friction stir welding tool while friction stir welding based at least in part on the positions of the tool and at least one of the parts. The position of the parts may be determined downstream of the friction stir welding tool in order to prospectively account for the position of the parts. Accordingly, the position of the friction stir welding tool may be dynamically adjusted during friction stir welding to account for part movement. Related systems and computer code are provided.

Abstract: In some implementations, an injection system that injects sealant into a pipe, pressure component or valve while containing the pipe, pressure component or valve repair that significantly reduces or eliminates release of hazardous material from inside the pipe, pressure component valve or injection system and thus significantly reduces emission of the hazardous material from inside the pipe, pressure component or valve into the environment and protecting the repair technicians.

Abstract: In some implementations, an injection system that injects sealant into a pipe, pressure component or valve while containing the pipe, pressure component or valve repair that significantly reduces or eliminates release of hazardous material from inside the pipe, pressure component valve or injection system and thus significantly reduces emission of the hazardous material from inside the pipe, pressure component or valve into the environment and protecting the repair technicians.

Abstract: Friction Stir Welding (FSW) devices and methods for simultaneously welding both sides of an arcuate joint are described. The FSW method includes the step of operating a FSW tool and an anvil on the exterior surface of the joint and simultaneously operating another FSW tool and anvil on the interior surface of the joint. The anvils are positioned in a juxtaposing manner to the FSW tools, and move in tandem with the FSW tools, thus providing a supporting force to the FSW tools during their operation.

Abstract: Disclosed is a friction stir welding tool (10) equipped with a probe (13) and a holder (16). At the tip of the probe (13) there is a pin part (11) and at the base there are probe-side protrusions (24) and probe-side recesses (25). At the tip of the holder (16) there are holder-side recesses (27) which mate with the probe-side protrusions (24), and holder-side protrusions (28) which mate with the probe-side recesses (25). External force applied to the probe (13) is transmitted from the probe-side protrusions (24) to the holder-side recesses (27) and from the probe-side recesses (25) to the holder-side protrusions (28).

Abstract: A welding tool for connecting at least two workpieces at a connection region by friction stir welding includes a shoulder that separates the connection region from the surroundings. The shoulder is designed as a molding tool to mold during the friction stir welding.

Abstract: A method is disclosed for controlling a process in which a component 4 is moved relative to another component 6 such that at least one of the components 4, 6 experiences a reduction in magnitude in at least one dimension. Such processes may include for example friction welding. The method comprises monitoring energy input to the process and adjusting an input parameter for the process based on the monitored energy input. The monitoring of energy input is performed before any reduction in component magnitude has begun to take place.

Abstract: A friction stir welding apparatus having a new cooling system that can cool a portion required to be cooled accurately and uniformly with a simple configuration, while suppressing unnecessary thermal expansion of a mounting jig includes a holding mechanism 20 having a holding member 22a movable with respect to a processing target member W so as to freely hold the processing target member W, in which the holding member 22a and a portion of a mounting jig 12 that can freely face the holding member 22a become paired, and a coolant supply source S that can freely supply a coolant to the paired holding member 22a and the portion of the mounting jig 12.

Abstract: In a friction stir welding apparatus that can control a penetrating position of a probe with respect to a processing target member to an optimum position at a time of friction stir welding by detecting a wear volume and a tip position of the probe, as a drive mechanism moves down a holder having a coefficient of thermal expansion larger than that of the probe and holding the probe, a detector can freely detect a length of a member including the holder and the probe, and a probe detection mechanism can freely detect a tip length, which is the length of the member of only the probe.

Abstract: A method for applying a wear reducing material to a tool used in a wellbore operation that includes welding a hardfacing alloy to a surface of the tool, wherein the welding comprises friction stirring the alloy into the tool's surface is disclosed. Methods of welding a preformed sleeve or width of wear reducing material using friction stirring are also disclosed.

Abstract: A method of manufacturing turbine engine casings having at least one boss includes, in one exemplary embodiment, forming an engine casing having an outer wall, machining a tapered opening through the casing outer wall, and machining a tapered portion in a metal plug where the tapered portion is sized to mate with the tapered opening in the casing outer wall. The method also includes inserting the metal plug into the tapered opening in the casing outer wall, and welding the metal plug to the casing.

Abstract: The present invention relates to tools and methods for disposing, coating, repairing, or otherwise modifying the surface of a metal substrate using frictional heating and compressive/shear loading of a consumable metal against the substrate. Embodiments of the invention include friction-based fabrication tooling comprising a non-consumable member with a throat and a consumable member disposed in the throat, wherein consumable filler material is capable of being introduced to the throat in a continuous manner during deposition using frictional heating and compressive/shear loading of the filler material onto the substrate. Preferred embodiments according to the invention include such tools operably configured for applying a force or displacement to the filler material during deposition.

Abstract: A counter-rotating spindle includes a shoulder tool, a pin tool inserted in the shoulder tool, a first motor that is connected with the pin tool and rotates the pin tool, and a second motor that is connected with the shoulder tool and rotates the shoulder tool. The direction and the speed of the rotation for the pin tool may be selected independently from the speed and direction of rotation of the shoulder tool enabling optimization of the friction stir welding process. Counter-rotating the pin tool and the shoulder tool may improve the mixing abilities and efficiency of the pin tool and may prevent the galling effect between the pin tool and the shoulder tool. The counter-rotating spindle may be used, for example, for continuous path friction stir welding and spot welding of aluminum and its alloys, including cast alloys, as well as joining similar and dissimilar alloys.

Abstract: A friction stir welding method in which a welding tool rotating around an axis is pressed against a welding target portion of workpieces supported by a backing member so that frictional heat is generated and the friction heat softens the welding target portion. The welding tool is at least partially inserted into the softened welding target portion and stirs the softened welding target portion so that the welding target portion is stir welded in a solid phase state. The friction stir welding method includes detecting a temperature of a temperature measurement point provided in the backing member, and calculating an estimated temperature of the welding tool from the detected temperature of the temperature measurement point, based on a predefined correlation between a temperature of the welding tool and a temperature of the backing member.

Abstract: A system and method for repairing and/or joining together multiple lengths of tubulars using friction stir joining, and a system for manipulating the tubular so that friction stir joining may be performed while the tubular is on a reel and/or at a field site.

Abstract: Provided are a friction processing tool in which a service life of the tool is improved and which can reduce a labor hour for manufacturing and a manufacturing cost, and a friction processing apparatus and a friction processing method using the same. In a friction working tool 20 for softening and processing workpieces W1 and W2 of a metal material by frictional heat generated by being pressed against the workpieces while being rotated, a cylindrical tool body 21 is provided, and a distal end surface of the tool body brought into contact with the workpieces W1 and W2 is formed only by a flat shoulder surface 22. The material of the friction processing tool 20 is made of Ni-based dual multi-phase intermetallic compound alloys.

Abstract: Devices and methods for friction stir welding using an anvil with a sacrificial material are disclosed. The method involves the steps of providing an anvil with a sacrificial material on the backside of the workpieces and operating a friction stir welding device to form a weld that joins the workpieces together with the sacrificial material. The anvil comprises a non-sacrificial base portion removably coupled with a sacrificial material.

Abstract: A welding tool for friction welding a workpiece, the tool including: a probe having a core including a ceramic material, the probe having a surface coating including a metallic material covering at least part of a contact zone of the probe.

Abstract: A friction stir welding (FSW) tool tip is described. The tool tip comprises a pin portion and a body portion that meet to form a shoulder. The tool tip has a graduated change in composition along its length. In some embodiments, the alloy composition near the end of the pin differs from the alloy composition of the body by at least 0.5% by wt of at least one element. A method of manufacturing a FSW tool tip having a gradual compositional change is also described.

Abstract: A friction welding tool having a pin and a clamping device with a counter bearing, a holddown element and a spring element. The pin has a coupling section for releasable, rotationally fixed coupling to a rotating output device of a machine tool. The counter bearing is held on the pin between the pin's coupling and engagement ends in a manner that allows the counter bearing to be axially immovable on but freely rotatable about a longitudinal axis of the pin. The holddown element surrounds the pin and is arranged on a side of the counter bearing facing the engagement end. The holddown element has a bearing surface for bearing on the workpiece arrangement. The spring element is provided between the holddown element and the counter bearing and is mounted on the pin in such a way that it is elastically slidable along the longitudinal axis of the pin.

Abstract: The present application relates to a friction stir welding tool (20) for joining two adjacent work pieces (10), which work pieces comprise portions (6) to be welded and having a narrow space there between on one side, said tool having an axis of rotation, and comprising a first shoulder (1), a second shoulder (2), and a pin (3) arranged so as to connect the first and second shoulders, wherein said first shoulder has a first contact surface for friction heat generation to the work pieces to be joined during welding, said first contact surface having a first contact area, and said second shoulder has a second contact surface for friction heat generation to an opposite surface (5) of the same portions of the work pieces to be joined, said second contact surface having a second contact area, the first and second areas having different sizes, where the first area is a larger sized area than the second area.