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

Abstract: Gradient polycrystalline cubic boron nitride (PCBN) materials are provided as well as tools incorporating such materials.

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.

Abstract: A linear friction welding system in one embodiment includes a ram configured to vibrate along a welding axis, a cam follower operably connected to the ram, an eccentric including an eccentric outer periphery operably engaged with the cam follower, and an inner periphery, a first power shaft slidingly engaged with the eccentric, and a second power shaft eccentrically engaged with the inner periphery.

Abstract: A friction stir welding method including: feeding a filler material through a first passage in a friction stir weld tool and into a substrate during friction stir welding of the substrate; and rotating the filler material with respect to the substrate while feeding the filler material. In this method, heat generated by rotational frictional contact of the filler material contributes to plasticization of the filler material.

Abstract: A friction surfacing apparatus and method for depositing one or more metals, metal alloys, or other materials is disclosed. The friction surfacing apparatus includes a pin tool holder, a non-consumable shoulder having an inside diameter and an outside diameter, the inside diameter terminating at an end wall and includes an angled side wall that forms a substantially frustoconical opening at one end, and a consumable pin tool coupled to the pin tool holder and at least partially protruding from the end wall of the shoulder. The shoulder is maintained at a predetermined distance from a surface of a workpiece such that the consumable pin tool deposits pin tool material onto the surface of the workpiece during a friction surfacing operation.

Abstract: In a metal material processing method, two metal materials are arranged to face each other in a processing portion, and a distal end of a rod-shaped rotary tool is inserted into the processing portion while rotating the rotary tool, thereby the two metal materials are processed. The distal end of the rotary tool has a probe protruding in a central portion and a shoulder in a peripheral portion. The probe and the shoulder are constituted by different materials in at least surface portions that are in contact with the metal materials.

Abstract: Friction stir methods are disclosed for processing at least one workpiece using a rotary tool with rotating member for contacting and processing the workpiece. The methods include oscillating the rotary tool laterally with respect to a selected propagation path for the rotating member with respect to the workpiece to define an oscillation path for the rotating member. The methods further include obtaining force signals or parameters related to the force experienced by the rotary tool at least while the rotating member is disposed at the extremes of the oscillation. The force signals or parameters associated with the extremes can then be analyzed to determine a lateral position of the selected path with respect to a target path and a lateral offset value can be determined based on the lateral position. The lateral distance between the selected path and the target path can be decreased based on the lateral offset value.

Abstract: A device for use with a welding apparatus, such as a friction stir spot welding (FSSW) apparatus, that maintains work pieces in a generally flat or flush orientation during a welding operation. The device can be mounted to the operable end of an FSSW apparatus so that it exerts a stabilizing force against an upper work piece. The stabilizing force exerted by the device prevents the upper work piece from deflecting when the rotating tool of the FSSW apparatus passes through the upper work piece and penetrates into the lower work piece. In an exemplary embodiment, the device includes a housing component that slidably receives a movable component under the force of a biasing component.

Abstract: 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.

Abstract: A friction stir welding method includes providing a joining tool including a friction surface; providing a first workpiece and a second workpiece; arranging the first workpiece and second workpiece in position with a first joining surface abutting a second joining surface, a friction surface of a joining tool resisting at least one of the first treating surface and the second treating surface; positioning, rotating and moving the joining tool to rub and stir at least one of the first workpiece and the second workpiece, thus plasticizing at least part of the first workpiece and the second workpiece to join the first workpiece and the second workpiece.

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

Abstract: A friction stir weld apparatus having a linear drive actuator and a separate friction stir weld device. The linear actuator and the friction stir weld device are driven by concentric motors. In the preferred embodiment, the thrust member of the actuator is connected to the friction stir weld device within or adjacent to the friction stir weld device motor to advance and retract the friction stir weld device along a linear axis concentric with the actuator and friction stir weld device motors.

Abstract: Metallic materials having a melting point of at least 2000° C. are caused to abut against each other in a welding part. The rear face side of the welding part is covered by a backing member having a thermal conductivity of 30 W/mK or lower, and then a columnar probe of a rotary tool comprising an Ir alloy is inserted into the front face side of the welding part to weld the metallic materials together. On the front face side of the welding part, inactive gas is supplied into a shield cover. The rotary tool is moved along a longitudinal direction of the welding part while rotating the rotary tool, whereby the metallic materials are welded together. By using the rotary tool comprising an Ir alloy, the refractory metals can be welded to each other by means of friction stir welding.

Abstract: In a Friction Stir Welding process a load, applied through a rotating tool, frictionally heats, plasticizes and commingles selected regions of the workpieces while translating along the length of the joint. The load is supported by an anvil. The applied load inhibits relative motion of the workpiece and conventional anvils due to friction which requires application of higher translation forces and could lead to undesired surface blemishes. Thus conventional practice is to employ bulky, stationary anvils. Compact, moveable anvils comprising freely-rotating or freely moving elements in contact with the workpieces and capable of reducing workpiece-anvil friction are described. Particular benefits of this anvil design are illustrated for the process of assembling inner and outer sheet metal components into an automobile assembly, a portion of which is visible to a vehicle customer.

Abstract: A method of joining a plurality of members to be joined together, by piling the plurality of members on one another and joining together the members with one another at end portions of superposed parts of the members, wherein the superposed parts of the members are held by restraining the superposed parts from both sides thereof, while a pressing tool, which is harder than the members, is pressed to end faces of the superposed parts and the pressing tool is rotated and/or moved relative to the superposed parts, so that the end faces of the superposed parts are rubbed to cause a friction heating which leads to cause a plastic flow, whereby the plurality of the members are joined together at the end portions of the superposed parts thereof.

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

Abstract: A method for producing a sputtering target assembly bonded to a backing plate. The method includes bonding a target (100) to a high strength backing plate (110) and further creating a vacuum seal between the target and the backing plate using friction stir welding processes.

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

Abstract: A method for controlling welding forces of a weld tip to a work piece during a vibration-welding process includes positioning an Active Material (AM) element adjacently to a welding interface, and varying a property of the AM element to regulate the welding force. The AM element may be disposed between the weld tip and a weld face thereof, or between the work piece and an anvil. The property may be varied as a function of heat generated by the welding process. A property of each of a plurality of AM elements may be independently and selectively varied via an energy source, or passively. A vibration welding system includes a weld tip and an AM element connected adjacently to a welding interface. The system regulates a welding force applied by the weld tip to a work piece during the welding process by varying a property of the AM element.

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

Abstract: A friction welding apparatus includes a first holder for holding a first work piece, a second holder for holding a second work piece, a thrust mechanism and a shaft. The thrust mechanism moves the second holder toward or away from the first holder. The shaft is connected to the first holder and the second holder for receiving thrust caused by the thrust mechanism. The shaft has a tie rod and an externally threaded member which is coaxially connected to the tie rod so that the externally threaded member is rotatable on an axis thereof. The thrust mechanism has the externally threaded member, an internally threaded member and a thrust motor. The internally threaded member is provided in either one of the first holder and the second holder and engaged with the externally threaded member. The thrust motor rotates the externally threaded member relative to the internally threaded member.

Abstract: A friction-welding device for the integral joining of components, having an oscillator, which generates a periodic movement of a component and a welding surface provided thereon relative to another, static component and a welding surface provided thereon, with directions of movement parallel to the welding surfaces, having a compression device which presses the welding surfaces together, and a cartridge which accommodates the moved component. The oscillator includes two or a greater, even number of piezoactuators, which are arranged in pairs on a line of application and are able to be prestressed with respect to the cartridge from opposite sides under pressure generation and are able to be moved in a synchronous, oscillating manner together therewith and the component.

Abstract: This invention relates to a friction welding apparatus, and more particularly, but not exclusively, to a modular friction welding apparatus suitable for in-situ reparation of blind holes in pipes. The friction welding apparatus includes a frame assembly, a spindle assembly for holding a friction welding consumable; and a drive assembly for driving a spindle of the spindle assembly. The spindle assembly and the drive assembly are releasably securable to the frame assembly so as to form a modular friction welding apparatus, and the frame assembly is furthermore removable securable to an object to be welded.

Abstract: A method of selecting a geometry for a friction stirring tool, said tool having a melting point that is higher than the workpiece material, wherein the tool is placed in motion against the workpiece to generate heat in the workpiece such that workpiece material is transported in surface features of the tool, and wherein surface features manage workpiece material flow around the tool, and wherein the tool can be used in friction stir processing, friction stir mixing, friction stir welding, and friction stir spot welding of high melting temperature materials or high softening temperature materials.

Abstract: A frictionally press-bonded member includes a steel pipe, and a stab. The steel pipe has opposite ends. The stab is frictionally press-bonded to at least one of the opposite ends of the steel pipe. The steel pipe is subjected to a normalizing treatment before being frictionally press-bonded to the stab.

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.

Abstract: Two tubular components (10, 14) are provided with integral end caps (11, 15). The end caps (11, 15) are placed in abutting relationship and are held together under pressure whilst the tubular component (10) is rotated. A pressure is applied and this causes frictional heating. A friction welded joint (18) occurs at the interface between the two end caps (11, 15). On completion of the welding process a machining tool is then passed through the internal bore (12 or 16) in either of the tubular components. The machining tool cuts through the joined end caps (11, 15) to produce a single uniform bore thorough the joined components. In a further post processing operation the extruded flash (20) is removed from the outer surfaces (13, 17).

Abstract: A friction stir welding tool is provided, wherein the tool includes a body; a neck formed integrally with the body, wherein the outer diameter of the neck is less than the outer diameter of the body; and a frustoconical probe formed integrally with the neck, wherein the probe further includes a base and a tip, wherein the outer diameter of the tip is less than the outer diameter of the base, wherein the outer diameter of the base is less than the outer diameter of the neck, wherein the outer edge of the base and the outer edge of the neck define a shoulder region therebetween, and wherein the ratio of the outer diameter of the neck and the outer diameter of the base is within the range of about 1.5:1 to 1.25:1 or less.

Abstract: A welding method and apparatus are provided for forming a weld joint between first and second elements of a workpiece. The method includes heating the first and second elements to form an interface of material in a plasticized or melted state interface between the elements. The interface material is then allowed to cool to a plasticized state if previously in a melted state. The interface material, while in the plasticized state, is then mixed, for example, using a grinding/extruding process, to remove any dendritic-type weld microstructures introduced into the interface material during the heating process.

Abstract: A friction welding machine (1) has two headstocks (5, 6), two spindles (8, 9) with a spindle drive (12, 13) and a workpiece holder (22). The first headstock (5) is arranged stationarily at the frame (2). The second headstock (6) is mounted axially movably at the frame (2) and is connected to a feed drive (25). The spindles (8, 9) have different sizes, the second spindle (9) and its spindle drive (13) being designed to be smaller and weaker.

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

Abstract: A friction stir method includes providing a joining tool, a mold comprising a top surface and a cutout defined from the top surface, and a workpiece comprising a treatable layer and arranged on the top surface of the mold. The joining tool resists the workpiece, and rotates and moves to agitate the treatable layer of the workpiece along an extending direction of the cutout of the mold, until a protrusion integrated with the workpiece is formed in the cutout of the mold.

Abstract: Method for the metallic joining of profiled rails in the longitudinal direction. Method includes heating rail ends to a joining temperature by pressing together faces of the rails end while simultaneously moving them relative to one another in an oscillating manner with a greatest oscillation amplitude relative to one another perpendicular to the main axis direction Y with the maximum moment of inertia of the cross-sectional surface, aligning the rail ends, and pressing the faces together to join the rails together.

Abstract: A friction stir welding method utilizes a joining tool comprising a friction surface; a first workpiece comprising a first treating layer, a second workpiece comprising a second treating layer, and a joining member with a melting point lower than that of the first workpiece and the second workpiece. The joining member is arranged at the joining portion of the first workpiece and the second workpiece, and abutting the first workpiece and the second workpiece. The friction surface of the joining tool is positioned to resist at least one of the first treating layer and the second treating layer. The joining tool is rotated and moved to agitate at least one of the first workpiece and the second workpiece, until at least part of the first workpiece and the second workpiece are plasticized and joined together.

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

Abstract: One side of a metal sheet is joined to a polymer layer by applying heat to a joining area on the opposite side of the metal. The heat flows through the thin metal to activate a thermoplastic material or heat setting polymer into a bond with the metal. The method can be used to bond the metal sheet to a plastic body or another metal member. It is preferred to use a friction or friction stir tool to heat the metal surface.

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: An apparatus for bearing a tool against a workpiece includes: (a) a pneumatically driven motor unit rotating a drive shaft substantially about a longitudinal drive axis; (b) a process shaft coupled with the drive shaft for rotating the tool substantially about a longitudinal process axis; (c) a flywheel coupled with one shaft of the drive shaft and the process shaft; and (d) at least one urging unit coupled with at least one of the motor unit and the process shaft. The urging unit moves the tool with respect to the workpiece. The flywheel and the one shaft impart inertial rotational energy to the tool after the pneumatic motor achieves a predetermined rotational speed.

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 substrate defining a recessed pattern therein, and at least one structural member positioned within the recessed pattern to at least partially secure the structural member therein. The structural member is positioned adjacent to the substrate and within the recessed pattern such that the substrate and structural member are formed of materials capable of being friction stir welded together.

Abstract: A process for friction stir welding at least a first part made of metal alloy A with at least a second part made of a dissimilar metal alloy B, in which the first and second parts are placed side by side, and a joint is made between the first and second parts using a rotating tool moving at a speed referred to as the travel speed. The tool travel speed has at least two alternated modes in continuous service, a first mode wherein a first average travel speed S1 and a second mode wherein a second average travel speed S2 is used, the speeds S1 and S2 being significantly different, typically at least 30% of the highest travel speeds, with the slowest advance speed being zero. The assemblies welded according to the invention are particularly advantageous for the fabrication of panels or structural sections used in the manufacture of transport vehicles.

Abstract: In a friction stir welding apparatus for overlapped joints provided with a rotor having a shoulder and a probe that is provided so as to protrude from the shoulder of the rotor and also so as to be disposed concentrically with the center axis of the rotor, a helical groove is formed in the peripheral surface of the probe, from the tip of the probe toward the shoulder, and the depth of the groove is formed so as to gradually decrease from the tip of the probe toward the shoulder.

Abstract: The invention relates to a double shouldered welding device for the friction stir welding of parts, in which at least one shoulder has two concentric rings providing two plane concentric bearing surfaces, the rings being arranged so that the smaller-diameter ring is capable of compressing the stirred material of the parts to be welded during advance of the welding device and so that the larger-diameter ring is capable of forming a sink-in stop for the smaller-diameter ring. The invention also relates to a method of friction stir welding by means of the welding device according to the invention, in which said device is force-driven.

Abstract: An apparatus for induction friction solid state welding a body having a work piece receiving bore. A stationary chuck is provided for securing a first tubular workpiece in the bore. A moving chuck is provided for securing a second tubular workpiece in bore. An induction heating coil is movable between an operative position and a stored position. An expandable cylinder moves the moving chuck toward and away from the stationary chuck. A torque transmission collar is used to rotate the moving chuck.

Abstract: Friction stir welding equipment control force spindle for mounting in an orbital head housing uses a coaxial sensor to measure downforce. Simultaneously, an axial electrical actuator is controlled to dynamically correct the axial tool position during the welding, by a direct axial force system control, in order to maintain controlled downforce according to parameters previously set, based on numerical control. The equipment also sets up, monitors and controls spindle rotation speed, welding speed, acceleration speed and downforce using for example closed loop control functions. A laser system may scan the backing surface before welding and correct original tool path, in order to get an offset tool path. A precision alarm system may provide safe welding while preventing the tool from colliding with the backing surface.

Abstract: Apparatus for connecting at least two plates (1, 2) of which a supporting plate (1) comprises a higher strength than a supported plate (2) posed thereon. By means of a connecting element (5) rotated by a rotational feeder unit (11), the connecting element with a collar (6) presses the supported plate (2) onto the supporting plate (1). With a shaft (10) a friction welding connection to the supporting plate (1) is made. The rotational feeder unit (11) is provided with a measurement device with measures an axial force exerted by the rotational feeder unit as well as a respective feeding motion and which indicates, upon abutment of the shaft of the connecting element onto the supporting plate, the pressure increase encountered therein, which, thereby, advances the rotational feeder unit, the feeding motion of which is adjustable to at least three sequential connecting stages.

Abstract: A method of mitigating distortion in a friction stir weld joint as well as an associated friction stir weld assembly for mitigating distortion in a friction stir weld joint are provided. In this regard, a workpiece having a friction stir weld joint and associated distortion may be provided. Force may then be selectively applied to the workpiece along at least a portion of friction stir weld joint. The application of force induces plastic deformation along at least the portion of the friction stir weld joint in order to reduce the distortion of the workpiece. Force may be applied, for example, by moving a roller, such as a hardened cylindrical roller having chamfered edges, along at least a portion of the friction stir weld joint in order to apply a compressive force.

Abstract: A new control variable is introduced, that when combined with previous dependent control criteria on other variables results in a control program that can create a superior weld while minimizing wear on the FSW tool, wherein the tool repeatedly experiences the same thermal and mechanical loading within specified control windows during every repeated weld sequence because flow stresses and tool loads are driven by temperature, and dependent control loops account for differences in material and heat that is transferred at different rates in varying locations throughout a friction stir weld.

Abstract: An attaching construction includes a first member having a circular tubular welding portion at a distal end and, at a rear end thereof, a holding portion which is integral with the welding portion. The attaching construction includes a second member having an annular first positioning rib, and an annular second positioning rib inside the first positioning rib. The welding portion is positioned within the first positioning rib, and the welding portion is friction welded in place within the first positioning rib while the first member is rotated.

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