Including Means To Provide Heat By Friction Between Relatively Moving Surfaces (i.e., Friction Welder) Patents (Class 228/2.1)
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Patent number: 8479391Abstract: A method of repairing an integrally bladed rotor includes the steps of placing a support collar around at least a leading and trailing edge portions of the blade stub, and performing linear friction welding to add a replacement airfoil to the blade stub. The linear friction welding is generally along a direction between the leading and trailing edges. In addition, the support collar leading and trailing edge portions are connected together.Type: GrantFiled: December 16, 2009Date of Patent: July 9, 2013Assignee: United Technologies CorporationInventors: Herbert A. Chin, Robert P. Schaefer, Eberhardt Privitzer, Wangen Lin, Billie W. Bunting, James J. Moor, Vincent Nevins, Jr., Andrew L. Haynes, Greg Czeladko, Kenneth T. Raczewski
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Publication number: 20130168436Abstract: The invention relates to a device for producing a weld seam on work pieces by means of friction stir welding, said device having a welding head (5) with a rotating friction stir welding tool (4), the welding head being guided along the joining region and supported with respect to the work piece (1). In said device an irrecoverable tension rod (3) is provided for support, said rod being able to penetrate the welding region, being supported with its lower end on the work piece (1) in a tensioned manner, and carrying a rail (3b) on its upper end for supporting a counter piece (6) that is mechanically connected to the welding head (5) or to the friction stir welding tool (4). An additional supplementary tool (9) working, when seen in the direction of welding, in front of the friction stir welding tool (4) is provided for removing the upper section (3e) of the tension rod protruding above the welding plane from the welding region.Type: ApplicationFiled: August 10, 2011Publication date: July 4, 2013Applicant: Stirzone OGInventors: Gunter Figner, Gunter Figner
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Patent number: 8469255Abstract: The present disclosure concerns a method for assembling aluminum alloy parts, in which (i) at least a first aluminum alloy part is procured in a solution heat treated, quenched, optionally cold worked, and naturally aged at ambient temperature or pre-aged temper, and at least a second aluminum alloy part, (ii) said parts are welded to obtain a welded assembly having a welded zone, (iii) cold working the entire welded zone between 0.3% and 5% is performed, (iv) the welded assembly thus cold worked undergoes post-weld aging to obtain a final metallurgical temper.Type: GrantFiled: May 3, 2010Date of Patent: June 25, 2013Assignee: Constellium FranceInventors: Isabelle Bordesoules, Armelle Danielou, Christine Henon, Philippe Lequeu
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Patent number: 8469256Abstract: A control parameter ramp profile that enables control parameters to be modified in a non-linear manner, such that as a temperature set point of a tool or a weld is approached, the control parameter ramp profile enables the temperature set point to be approached in a manner that prevents temperature overshoot and therefore creating a better weld along the length thereof, wherein the control parameter ramp profile includes but is not limited to proportional, exponential or an S-curve waveform.Type: GrantFiled: December 13, 2011Date of Patent: June 25, 2013Assignee: MegaStir Technologies LLCInventors: Jonathan A. Babb, Russell J. Steel, Scott M. Packer, John Williams
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Publication number: 20130139968Abstract: A linear friction welding system includes a power shaft defining a power shaft axis and including a first eccentric portion and a first power transfer portion, a power transfer rod engaged with the first power transfer portion, an actuator assembly operably coupled with the power transfer rod and configured to move the power transfer rod axially along the power shaft axis, a crank including a second eccentric portion operably coupled with the first eccentric portion, and a second power transfer portion engaged with the power transfer rod, the linear friction welding system configured such that axial movement of the power transfer rod causes rotational movement of the crank with respect to the power shaft about the power shaft axis, a cam follower operably connected to an outer surface of the second eccentric portion, and a ram operably connected to the cam follower and configured to vibrate along a welding axis.Type: ApplicationFiled: December 1, 2011Publication date: June 6, 2013Applicant: APCI, LLCInventor: Stephen A. Johnson
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Publication number: 20130134206Abstract: 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.Type: ApplicationFiled: November 21, 2012Publication date: May 30, 2013Applicant: Helmholtz-Zentrum Geesthacht Zentrum für Material - und Küstenforschung GmbHInventor: Helmholtz-Zentrum Geesthacht Zentrum für Materi
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Publication number: 20130126588Abstract: Tools for friction stir welding can be made with fewer process steps, lower cost techniques, and/or lower cost ingredients than other state-of-the-art processes by utilizing improved compositions and processes of fabrication. Furthermore, the tools resulting from the improved compositions and processes of fabrication can exhibit better distribution and homogeneity of chemical constituents, greater strength, and/or increased durability. In one example, a friction stir weld tool includes tungsten and rhenium and is characterized by carbide and oxide dispersoids, by carbide particulates, and by grains that comprise a solid solution of the tungsten and rhenium. The grains do not exceed 10 micrometers in diameter.Type: ApplicationFiled: January 22, 2013Publication date: May 23, 2013Applicant: BATTELLE MEMORIAL INSTITUTEInventor: BATTELLE MEMORIAL INSTITUTE
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Patent number: 8444040Abstract: An apparatus includes a connector and is configured to mount to a machine having multiple axes of control. A control signal on the connector determines a path of a rotating tool holder.Type: GrantFiled: February 10, 2010Date of Patent: May 21, 2013Assignee: Wichita State UniversityInventor: Dwight A. Burford
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Publication number: 20130119115Abstract: A friction stir welding device (1) includes a workpiece disposition unit (2) at which workpieces (W) is disposed, a main body section (3) disposed at a surface (W4) of the workpieces (W) disposed at the workpiece disposition unit (2), a tool holding unit (4) formed in the main body section (3) to enable advance and retreat in a direction facing the workpieces (Z), which is a direction approaching and separating from the workpieces (W) disposed at the workpiece disposition unit (2), and configured to hold a tool (100), and a support medium (5) formed to satisfy a predetermined relative positional relationship in the direction facing the workpieces (Z) with respect to a first shoulder surface of the tool (100) attached to the tool holding unit (4) and configured to support the tool holding unit (4) on the surface (W4) of the workpieces (W) disposed at the workpieces disposition unit (2).Type: ApplicationFiled: May 27, 2011Publication date: May 16, 2013Inventors: Yoshinori Kato, Satoshi Furutate, Toshiyuki Kinoshita
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Patent number: 8439250Abstract: A method for joining a tube and tube plate for use in a tube-and-shell heat exchanger is disclosed. The method enables a joint between the tube and tube plate that is substantially hermetic and substantially corrosion-resistant. The method comprises providing an anvil inside the tube, wherein the anvil supports the tube wall during a friction-stir welding process used to join the tube and tube plate. The anvil facilitates formation of a reliable weld region and enables faster friction-stir welding.Type: GrantFiled: July 1, 2010Date of Patent: May 14, 2013Assignee: Lockheed Martin CorporationInventors: Riki P. Takeshita, Randy J. Brown, Michael R. Eller, Duy N. Pham
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Publication number: 20130112736Abstract: A member support of a friction stir spot welding device has a backing piece having a bearing surface that contacts work-pieces, and a supporting body that supports the backing piece. In the backing piece, the amount of change (?) in the position of the bearing surface on the extension line of the central axis of rotation between a state in which the bearing surface is in a reference state perpendicular to the central axis of rotation (Ac) of a rotary tool) and a state in which the bearing surface tilts in response to the tilting of the work-pieces, is less than or equal to a predetermined embedding amount (ds) with which the shoulder part of the rotary tool is embedded in the work-pieces.Type: ApplicationFiled: December 16, 2010Publication date: May 9, 2013Inventor: Yoshinori Kato
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Patent number: 8434661Abstract: A friction stir welding tool and process for lap welding dissimilar materials are detailed. The invention includes a cutter scribe that penetrates and extrudes a first material of a lap weld stack to a preselected depth and further cuts a second material to provide a beneficial geometry defined by a plurality of mechanically interlocking features. The tool backfills the interlocking features generating a lap weld across the length of the interface between the dissimilar materials that enhances the shear strength of the lap weld.Type: GrantFiled: June 14, 2012Date of Patent: May 7, 2013Assignee: Battelle Memorial InstituteInventors: Yuri Hovanski, Glenn J. Grant, Saumyadeep Jana, Karl F. Mattlin
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Patent number: 8434660Abstract: A spindle head for performing friction stir welding includes concentric spindle shafts driven by stacked, coaxial motors contained within a spindle housing. The coaxial arrangement of the motors results in a more compact package. Each of the motors is concentrically arranged around one of the spindles by directly connecting a rotor of the motor to a spindle shaft. The stators of the motors are mounted on the housing and are concentrically arranged around the concentric spindle shafts.Type: GrantFiled: August 30, 2011Date of Patent: May 7, 2013Assignee: The Boeing CompanyInventors: Kurt A. Burton, Mike P. Matlack, John Baumann, Herb Bommer
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Patent number: 8434662Abstract: A method of welding that realizes enhancements of airtightness and watertightness at a weld area and a method of welding and method of friction stir welding that attain an enhancement of welding operation efficiency/speed. There is provided a method of welding including the first primary welding step of carrying out a friction stir welding on the abutting portion (J1) of metal members (1,1) from the surface (12) side of metal member (1) and the second primary welding step of carrying out a friction stir welding on the abutting portion (J1) from the reverse face (13) side of the member (1), wherein in the second primary welding step, the friction stir welding is performed while penetrating a stirring pin (B2) of rotation tool (B) in plasticized region (W1) formed in the first primary welding step.Type: GrantFiled: September 5, 2012Date of Patent: May 7, 2013Assignee: Nippon Light Metal Co., Ltd.Inventors: Hayato Sato, Hisashi Hori
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Publication number: 20130098526Abstract: A friction stirring and joining apparatus includes a tool holder; and pressing means provided ahead in the direction of joining by a tool held by the tool holder for pressing a junction surface of a workpiece. The pressing means includes a load imparting section that imparts a load toward the workpiece; a first abutting portion that is provided between the load imparting section and the tool held by the tool holder and abuts on the junction surface in the workpiece; a second abutting portion that is provided opposite the first abutting portion with respect to the load imparting section and abuts on the surface of the workpiece; and a supporting portion that is attached to the load imparting section and supports the first abutting portion and the second abutting portion.Type: ApplicationFiled: August 21, 2012Publication date: April 25, 2013Inventor: Yoshinori KATO
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Publication number: 20130087604Abstract: A friction stir welding tool is provided which allows for excellent wear resistance and high joining strength even in a process of joining difficult-joining materials. A friction stir welding tool of the present invention is used for a friction stir welding process and includes a base material. The base material includes a hard phase and a binder phase. The hard phase includes TiCN. The binder phase is made of an iron group metal. A mass ratio Bs of the binder phase to the base material in a region having a thickness of 20 ?m from a surface of the base material is smaller than a mass ratio Bi of the binder phase to the base material in a region beyond the thickness of 20 ?m from the surface of the base material.Type: ApplicationFiled: December 27, 2011Publication date: April 11, 2013Applicant: SUMITOMO ELECTRIC INDUSTRIES, LTD.Inventors: Hideki Moriguchi, Yoshiharu Utsumi, Hiroka Miyazaki
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Publication number: 20130086783Abstract: A joining apparatus for joining together structural components of an aircraft, includes positioning means for holding the structural components to be joined in a defined desired position, in which the structural components can be fixedly joined together by means of a joining device that can be moved relative to the structural components by way of guiding means, wherein the positioning means encompass a formative frame structure that is detachably secured to the structural components to be connected along the joining edges outside in the edge area, and serves as a guiding means for the joining device movably secured hereupon.Type: ApplicationFiled: October 3, 2012Publication date: April 11, 2013Applicant: AIRBUS OPERATIONS GMBHInventor: AIRBUS OPERATIONS GMBH
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Patent number: 8413875Abstract: A multi-shouldered friction stir welding tool comprises an exterior threaded solid pin having a diameter and a length; a shoulder having a threadless inner diameter slightly larger than the diameter of the exterior threaded solid pin and at least one substantially radial threaded set screw hole; an monolithic shoulder-shank having a threadless inner diameter slightly larger than the diameter of the exterior threaded solid pin and at least one substantially radial threaded set screw hole; a pair of locking nuts having a threadless outer diameter and a threaded inner diameter operably compatable with the exterior threaded solid pin, wherein the shoulder and the monolithic shoulder-shank are capable of slidable engagement with the exterior threaded solid pin along the length of the exterior threaded solid pin to set a space slightly larger than a thickness of a work piece to be welded.Type: GrantFiled: July 30, 2012Date of Patent: April 9, 2013Assignee: Alcoa Inc.Inventors: Israel Stol, John W. Cobes, Trent A. Chontas, Joseph M. Fridy
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Publication number: 20130082088Abstract: A method for repairing an aircraft component includes removing a portion of the aircraft component to create an opening within the aircraft component. The method also includes creating a patch, inserting the patch into the opening such that a welding location is defined, and coupling the patch to the aircraft component using a friction stir welding process. The friction stir welding process includes inserting a portion of a friction stir welding device into the welding location. The method also includes causing the portion of the friction stir welding device to enter an interior of the patch and removing the portion of the friction stir welding device from the patch at the ramp.Type: ApplicationFiled: September 25, 2012Publication date: April 4, 2013Applicant: General Electric CompanyInventor: General Electric Company
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Patent number: 8408444Abstract: It is an object to provide a friction stir tool excellent in productivity, high temperature strength, and wear resistance at high temperatures. The friction stir tool is formed of a Co-based alloy comprising crystal grains containing a ?? precipitate phase dispersed and precipitated therein, and a crystal grain boundary region and a precipitate phase between adjacent crystal grains, in which the precipitate phase is at least one phase selected from a ? phase, a Laves phase and a carbide phase.Type: GrantFiled: August 20, 2010Date of Patent: April 2, 2013Assignees: Hitachi, Ltd., Tohoku UniversityInventors: Seunghwan Park, Satoshi Hirano, Shinya Imano, Jun Sato, Hiroyuki Kokawa, Yutaka Sato, Kiyohito Ishida, Toshihiro Omori
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Patent number: 8408443Abstract: Modular friction welding heads and associated systems and methods are disclosed herein. A friction welding system in accordance with a particular embodiment includes a carrier fixture positioned to carry a workpiece, a head support positioned proximate to the carrier fixture, and a modular friction welding head releasably carried by the head support. At least one of the carrier fixture and the head support can have a guide structure with a constrained motion path positioned to guide relative motion between the modular friction welding head and the carrier fixture. A controller can be operatively coupled to the modular friction welding head and programmed with instructions to control the operation of the friction welding head.Type: GrantFiled: February 18, 2010Date of Patent: April 2, 2013Assignee: Blue Origin, LLCInventors: Ray Miryekta, Christopher M. Gil
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Patent number: 8408445Abstract: A vibration welding system includes a controller, welding horn, an active material element, and anvil assembly. The assembly may include an anvil body connected to a back plate and support member. The element, e.g., a piezoelectric stack or shape memory alloy, is positioned with respect to the assembly. The horn vibrates in a desirable first direction to form a weld on a work piece. The element controls any vibrations in a second direction by applying calibrated response to the anvil body in the second direction. A method for controlling undesirable vibrations in the system includes positioning the element with respect to the anvil assembly, connecting the anvil body to the support member through the back plate, vibrating the horn in a desirable first direction, and transmitting an input signal to the element to control vibration in an undesirable second direction.Type: GrantFiled: March 1, 2012Date of Patent: April 2, 2013Assignee: GM Global Technology Operations LLCInventors: Wayne W. Cai, Bongsu Kang, Chin-An Tan
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Publication number: 20130075452Abstract: A mandrel tool probe is provided for performing a friction-stir process. The mandrel tool probe includes a shank and a tip coupled to the shank, where the shank and tip are concentric and rotatable about a given axis. The tip includes a set of a plurality of physically-separate, spiraled surfaces each of which has a linear or curved cross-section that extends along a length of the tip at a constant or varying spiral angle around the circumference of the tip. The tip also has a cross-section with a constant shape along the length of the tip, with the cross-section of the tip including a plurality of major segments each of which is formed of the cross-section of a respective spiraled surface.Type: ApplicationFiled: September 20, 2012Publication date: March 28, 2013Inventor: Dwight A. Burford
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Publication number: 20130068825Abstract: A system and method for modifying a work piece surface of high melting temperature materials such as Advanced High Strength Steels, wherein a friction stir welding tool may include cutting elements located on the outside diameter of a collar assembly, wherein the collar assembly may be retrofitted for existing friction stir welding tools, or may be designed as a custom attachment for a new hybrid friction stir welding tool, wherein the surface of the work piece may be modified by removing detrimental flash and burr created during operation of the friction stir welding tool.Type: ApplicationFiled: September 20, 2012Publication date: March 21, 2013Applicant: MEGASTIR TECHNOLOGIES LLCInventor: MegaStir Technologies LLC
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Patent number: 8397928Abstract: A barrel made of wood, in particular oak wood, for containing a liquid, such as wine, the barrel comprising a hollow body closed by two barrel heads, each barrel head comprising an assembly of substantially rectangular wooden battens assembled parallel to one another via facing lateral faces, the barrel being characterized in that the adjacent lateral faces (101, 201) of two assembled-together battens (100, 200) are in intimate leaktight contact, with fibers of the wood of each of said battens being tangled together and held in a matrix of fused intercellular materials.Type: GrantFiled: September 25, 2008Date of Patent: March 19, 2013Assignee: Tonnellerie TaransaudInventors: Vincent Lefort, Christelle Ganne-Chedeville
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Patent number: 8397974Abstract: The present invention relates to tools and methods for welding, coating, repairing, or otherwise modifying the surface of a metal substrate. More specifically, embodiments of the present invention provide self-reacting friction stir welding tools which have an internal channel that allows filler materials to be added to the weld joint or otherwise friction stir processed area. Embodiments also provide friction stir tooling having upper and lower shoulders disposed at a fixed distance from one another and connected by a fixed split-pin. The tooling can be configured for automatically dispensing varying amounts of filler material into the tooling in response to variations in thickness of a substrate being processed.Type: GrantFiled: April 9, 2012Date of Patent: March 19, 2013Assignee: Aeroprobe CorporationInventors: Jeffrey Patrick Schultz, Kevin Creehan
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Publication number: 20130062395Abstract: 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: ApplicationFiled: November 5, 2012Publication date: March 14, 2013Applicants: BRIGHAM YOUNG UNIVERSITY, MEGASTIR TECHNOLOGIES LLCInventors: MEGASTIR TECHNOLOGIES LLC, BRIGHAM YOUNG UNIVERSITY
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Patent number: 8393523Abstract: A method of performing ultrasonic stir welding uses a welding head assembly to include a plate and a rod passing through the plate. The rod is rotatable about a longitudinal axis thereof. In the method, the rod is rotated about its longitudinal axis during a welding operation. During the welding operation, a series of on-off ultrasonic pulses are applied to the rod such that they propagate parallel to the rod's longitudinal axis. At least a pulse rate associated with the on-off ultrasonic pulses is controlled.Type: GrantFiled: June 14, 2012Date of Patent: March 12, 2013Assignee: The United States of America as represented by the Administrator of the National Aeronautics and Space AdministrationInventor: R. Jeffrey Ding
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Patent number: 8393519Abstract: The invention provides a method of assembling together two thin plane parts (1, 2) by friction welding. A main sheet (19) made of a material having high thermal conductivity is held against the parts (1, 2) for assembly. The main sheet (19) picks up the heat induced by the friction of a welding pin (5) against the parts (1, 2) for the purpose of forming the weld bead (17), and it dissipates this heat by radiation. Temperature regulation of the welding operation is obtained by the main sheet (19), ensuring that no localized excess heating occurs in the welding zone. The main sheet (19) is based on copper and presents a thickness that is less than the thickness of the parts (1, 2).Type: GrantFiled: March 16, 2010Date of Patent: March 12, 2013Assignee: EurocopterInventors: Delphine Allehaux, Jean-Loup Gatti
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Patent number: 8393520Abstract: An ultrasonic stir welding system includes a welding head assembly having a plate and a rod passing through the plate. The rod is rotatable about a longitudinal axis thereof. During a welding operation, ultrasonic pulses are applied to the rod as it rotates about its longitudinal axis. The ultrasonic pulses are applied in such a way that they propagate parallel to the longitudinal axis of the rod.Type: GrantFiled: September 22, 2011Date of Patent: March 12, 2013Assignee: The United States of America as Represented by the Administrator of the National Aeronautics and Space AdministrationInventor: R. Jeffrey Ding
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Patent number: 8393522Abstract: A joining method of a pair of workpieces, each workpiece having a non-flat portion and an abutting surface continuous to the non-flat portion, wherein the method provides an extension portion on each of the workpieces, the extension portion having a surface continuous with the non-flat portion and the abutting surface and projecting outward from the workpiece, and holding the workpieces so as to form a joining line between the non-flat portions of the respective workpieces by bringing the abutting surfaces thereof into contact with each other. Also disclosed is a joining tool having a substantially cylindrical shoulder portion and a projection projecting outward from a tip surface of the shoulder portion.Type: GrantFiled: January 4, 2012Date of Patent: March 12, 2013Assignee: Suzuki Motor CorporationInventors: Ryo Yamauchi, Kentaro Kobari
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Patent number: 8393524Abstract: 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.Type: GrantFiled: June 25, 2012Date of Patent: March 12, 2013Assignee: The Boeing CompanyInventors: Kurt A. Burton, Mike P. Matlack
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Patent number: 8393521Abstract: A method of producing a welded assembly from a first metal part and a second metal part includes bringing the first metal part and the second metal part into contact with one another at a joint region while providing a flash ring separator adjacent the joint region configured to intercept and separate flash. After heating the joint region, the first and second metal parts are forced together to join the first metal part to the second metal part, extruding metal flash from the joint region. The extruded flash impinges on the flash ring separator, forming a flash ring having at least one indentation. During subsequent machining of the welded assembly to remove the flash ring, the flash ring may fragment at the indentation, so that it does not cause damage by becoming hung around the assembly.Type: GrantFiled: December 20, 2011Date of Patent: March 12, 2013Assignee: Caterpillar Inc.Inventors: Dennis Sachaschik, Thomas K. Yeung, Russell D. Carpenter, Frank K. Anthony, Tom G. Hamric, Joy Elaine Allen, Marlon Cobbins, Joseph Paluga
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Publication number: 20130056525Abstract: A friction agitation welding process for the joining of abutting plate-shaped workpieces consisting of an aluminium alloy, wherein a rotating Bobbin tool is moved along a weld between the two plate-shaped workpieces during feed, exerting a first and a second contact pressing force on first and second sides, respectively, and wherein said Bobbin tool is subjected to an additional axial force during its movement along the weld to plastically deform the area of the created welding seam such that the welding seam is pressed towards one side of the plate-shaped workpieces while forming a welding seam elevation protruding opposite from the workpiece surface.Type: ApplicationFiled: August 30, 2012Publication date: March 7, 2013Applicant: AIRBUS OPERATIONS GMBHInventor: Hartmut Ostersehlte
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Patent number: 8387852Abstract: A method of making tailored blanks in accordance with one embodiment comprises the steps of: (a) friction welding first and second structural members together along a straight interface to form a weld joint, each of the first and second structural members having a respective polygonal profile that is not a parallelogram; and (b) machining the first and second structural members to form first and second curved contours that each intersect the weld joint.Type: GrantFiled: January 9, 2006Date of Patent: March 5, 2013Assignee: The Boeing CompanyInventors: Robert R. Bevans, Edward H. Gerding
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Publication number: 20130048786Abstract: 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.Type: ApplicationFiled: October 29, 2012Publication date: February 28, 2013Applicant: The Boeing CompanyInventor: The Boeing Company
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Patent number: 8376210Abstract: A linear friction welding system and method in one embodiment includes a first motor configured to rotate a first power shaft, a second motor configured to rotate a second power shaft, a memory including program instructions, and a controller operably connected to the first motor, the second motor, and the memory, and configured to execute the program instructions to identify a first current oscillation amplitude of a ram operably connected to the first power shaft and the second power shaft, determine a second desired oscillation amplitude for the ram, determine a minimum shift in relative angle between the first motor and the second motor to achieve the second desired oscillation amplitude, allocate the minimum shift in relative angle between the first motor and the second motor, and control the first motor and the second motor based upon the allocated minimum shift in relative angle.Type: GrantFiled: May 2, 2012Date of Patent: February 19, 2013Assignee: APCI, LLCInventors: Stephen A. Johnson, Thaddeus W. Gorski
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Patent number: 8371014Abstract: A method of forming a metallic container includes the steps of providing body and lid portions, placing the body and lid portions together, keeping portions of the body and lid portions in contact with one another, and reciprocally rotating the lid portion with respect to the body portion, thereby generating frictional heat and forming a friction weld therebetween. An apparatus for attaching the lid and body portions of a metallic container includes a base to support the body, a support assembly to support a flange of the body, and a sonitrode for contacting a flange of the lid, wherein the flanges of the lid and body are held together between the support assembly and the sonitrode. A motor reciprocally rotates the sonitrode relative to the support assembly, thereby moving the flanges relative one another to generate frictional heat and create a friction weld therebetween.Type: GrantFiled: January 20, 2010Date of Patent: February 12, 2013Assignee: New Sonic Technologies, LLCInventor: James T. Williamson
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Publication number: 20120325895Abstract: A multi-shouldered friction stir welding tool comprises an exterior threaded solid pin having a diameter and a length; a shoulder having a threadless inner diameter slightly larger than the diameter of the exterior threaded solid pin and at least one substantially radial threaded set screw hole; an monolithic shoulder-shank having a threadless inner diameter slightly larger than the diameter of the exterior threaded solid pin and at least one substantially radial threaded set screw hole; a pair of locking nuts having a threadless outer diameter and a threaded inner diameter operably compatable with the exterior threaded solid pin, wherein the shoulder and the monolithic shoulder-shank are capable of slidable engagement with the exterior threaded solid pin along the length of the exterior threaded solid pin to set a space slightly larger than a thickness of a work piece to be welded.Type: ApplicationFiled: July 30, 2012Publication date: December 27, 2012Applicant: ALCOA INC.Inventors: Israel Stol, John W. Cobes, Trent A. Chontas, Joseph M. Fridy
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Patent number: 8336755Abstract: A weld enclosure and welding apparatus including a weld enclosure. Also a method of welding. The apparatus has first and second opposed tooling faces adapted to receive and hold respective first and second weld elements. The weld enclosure comprises a housing that allows relative movement between the weld elements and a change in a physical dimension of at least one of the weld elements. The weld enclosure also comprises locating means for locating the housing relative to the welding apparatus and includes heating means.Type: GrantFiled: May 23, 2008Date of Patent: December 25, 2012Assignee: Rolls-Royce, PLCInventors: Simon E. Bray, Tony J. Sweeting
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Publication number: 20120318848Abstract: The object of the invention is to provide a rotary tool for friction stir welding having an excellent abrasion resistance and durability, which can attain an excellent joint characteristics. In a rotary tool 10 for friction stir welding, a shoulder portion 11 has an end surface 13 from which a prove pin 20 protrudes. The outer periphery of the prove pin 20 has a connection 15 linked to the end surface 13 of the shoulder portion 11. Pulse laser peening is applied to a base side region 22, that extends from the connection 15 to the screw part 23a. The prove pin, which is repetitiously exposed to compression load and tensile load during the friction stir welding, can maintain the surface rigidity and the toughness. The durability of the prove pin is greatly improved with the damages due to buckling or thermal deformation being restricted.Type: ApplicationFiled: July 13, 2010Publication date: December 20, 2012Inventors: Takafumi Adachi, Hiroyuki Takehisa, Yuji Sano, Itaru Chida
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Patent number: 8333314Abstract: A structure for joining members which is suited for joining of thin members together and suited for joining of members made of different materials. The structure includes a nut, a first member superposed on the nut such that a preliminarily formed hole on the first member is contiguous with the threaded hole of the nut, and a second member superposed on the first member so as to cover the hole.Type: GrantFiled: November 9, 2007Date of Patent: December 18, 2012Assignee: Hino Motors, Ltd.Inventor: Hiroshi Fukuda
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Publication number: 20120298724Abstract: In a bobbin tool including a first shoulder surface which comes into contact with a front surface of a subject work piece, a second shoulder surface which is disposed so as to face the first shoulder surface and comes into contact with a rear surface of the work piece, and a shaft portion which connects the first shoulder surface and the second shoulder surface to each other with a gap therebetween fixed, the first shoulder surface and the second shoulder surface are provided with a first vortex groove and a second vortex groove which extend toward the front side of a tool rotation direction so as to be opened to the outer peripheral edge as it moves to the outer peripheral side.Type: ApplicationFiled: January 11, 2012Publication date: November 29, 2012Inventors: Yoshinori KATO, Hiroaki Sato
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Publication number: 20120298304Abstract: Provided is a friction stir welding apparatus which performs friction stir welding on a work piece by bringing a tool into contact with a surface of the work piece and rotating and moving the tool about the axis thereof, the friction stir welding apparatus including: a hot air and cool air separating unit which separates a supplied gas into hot air hotter than the gas and cool air cooler than the gas and ejects the hot and cool air, wherein at least one of the hot air and the cool air is supplied to the surface of the work piece.Type: ApplicationFiled: January 11, 2012Publication date: November 29, 2012Inventor: Yoshinori KATO
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Publication number: 20120298727Abstract: One embodiment of a friction stir welding apparatus comprises two friction stir welding tools on a carriage. The first friction stir welding tool is capable of rotating in a first direction. The second friction stir welding tool is capable of rotating in a second direction, counter to the first direction. The first friction stir welding tool and the second friction stir welding tool are operable to weld simultaneously and in tandem along an intersection of at least two work pieces.Type: ApplicationFiled: May 24, 2012Publication date: November 29, 2012Applicant: ALCOA INC.Inventors: Israel Stol, James T. Burg
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Publication number: 20120298725Abstract: Inflatable rings for supporting friction welding workpieces, and associated systems and methods. A support assembly for joining multiple workpieces in a representative embodiment includes a carriage and a generally ring-shaped support member that in turn includes a body and at least one inflatable member carried by the body and positioned to expand from a first configuration to a second configuration.Type: ApplicationFiled: April 25, 2012Publication date: November 29, 2012Applicant: Blue Origin, LLCInventor: David M. Biggs
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Patent number: 8317079Abstract: A clinching method includes establishing a first layer on a second layer. The first layer has an aperture formed therein and is thinner than the second layer. A rotating punch is engaged with the second layer through the aperture in the first layer, thereby generating frictional heat and softening the second layer. The rotating punch is configured with at least a first diameter, a shoulder, and a second diameter that is larger than the first diameter. The rotating punch is pressed into the softened second layer, thereby causing at least some of the second layer to: back extrude through an annulus defined by the aperture in the first layer and at least one of the diameters of the punch; contact the shoulder of the rotating punch; and extend onto a surface of the first layer adjacent the aperture.Type: GrantFiled: October 8, 2008Date of Patent: November 27, 2012Assignee: GM Global Technology Operations LLCInventor: Jon T. Carter
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Publication number: 20120279442Abstract: The present invention relates to tools and methods for welding, coating, repairing, or otherwise modifying the surface of a metal substrate. More specifically, embodiments of the present invention provide self-reacting friction stir welding tools which have an internal channel that allows filler materials to be added to the weld joint or otherwise friction stir processed area. Embodiments also provide friction stir tooling having upper and lower shoulders disposed at a fixed distance from one another and connected by a fixed split-pin. The tooling can be configured for automatically dispensing varying amounts of filler material into the tooling in response to variations in thickness of a substrate being processed.Type: ApplicationFiled: April 9, 2012Publication date: November 8, 2012Inventors: Kevin Creehan, Jeffrey Patrick Schultz
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Publication number: 20120279441Abstract: 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.Type: ApplicationFiled: April 9, 2012Publication date: November 8, 2012Inventors: Kevin Creehan, Jeffrey Patrick Schultz
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Patent number: RE43846Abstract: 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.Type: GrantFiled: April 5, 2012Date of Patent: December 11, 2012Assignee: Nissan Motor Co., Ltd.Inventors: Akihiko Sano, Yoshitaka Miura