Abstract: A method of manufacturing a hollow coil spring which is made of a hollow wire in which a terminal sealed portion is formed on an end portion of the wire. The terminal sealed portion has a rotationally symmetric shape in which an axis passing through the center of the wire is the symmetric axis. The hollow coil spring includes an end wall portion, and an end face arc-shaped curved surface. The end wall portion includes an end face perpendicular to the axis. A distal-end-center closure portion is formed on the axis at the center of the end wall portion. A spring seat includes a base member and a sheet member. An end turn portion of the hollow coil spring is in contact with the sheet member. The end face of the end turn portion is opposed to a stopper wall of the spring seat.

Abstract: A pneumatic motor propulsion source including a friction welding apparatus, a gas accumulator tank operably coupled to the friction welding apparatus, and an air compressor operably coupled to the gas accumulator tank.

Abstract: A friction stir spot welding method includes a welding step of performing friction stir spot welding of a workpiece by using a pin member and a shoulder member while the workpiece is supported and pressed by the end face of a clamp member and a pressing step of causing a friction stir spot welding device to press an obverse surface and a reverse surface of at least one of a friction-stirred region of the workpiece and an adjacent region adjacent to the friction-stirred region of the workpiece from a rotary tool side and an opposite side after the welding step while the pin member and the shoulder member are accommodated in an accommodation space of the clamp member.

Abstract: Disclosed is a friction welding method including: a heating step wherein, in relation to joining surfaces (S1, S2) defined by opposite end surfaces of a pair of materials (W1, W2), the pair of materials (W1, W2) are moved from a state in which their axes are unaligned with each other, in a direction for aligning the respective axes with each other, to a prescribed position where the joining surfaces (S1, S2) are brought into contact with each other and friction heated; and a pressure contacting step wherein the pair of materials are brought into pressure contact with each other. The method is characterized in that the heating step and the pressure contacting step are carried out while rotating each of the materials (W1, W2) at the same rotation speed in the same direction, as seen from one side in the axial direction.

Abstract: The present disclosure provides a system and method for measuring energy conversion efficiency of an inertia friction welding (IFW) process in a non-contact manner. The system includes an IFW machine, a Hall sensor, a data acquisition module, a processing module and a stabilized direct current (DC) power supply. The stabilized DC power supply provides electrical energy for the Hall sensor. The Hall sensor is provided beside a flywheel of the IFW machine, so that the flywheel is within a detection range of the Hall sensor. A magnet is provided on the flywheel. The data acquisition module acquires a Hall electric potential change caused by a relative movement between the magnet and the Hall sensor during the IFW process, and transmits the Hall electric potential change to the processing module to calculate the energy conversion efficiency of the IFW machine.

Abstract: The present invention provides a method for stabilizing a fractured bone. The method includes positioning an elongate rod in the medullary canal of the fractured bone and forming a passageway through the cortex of the bone. The passageway extends from the exterior surface of the bone to the medullary canal of the bone. The method also includes creating a bonding region on the elongate rod. The bonding region generally aligned with the passageway of the cortex. Furthermore, the method includes positioning a fastener in the passageway of the cortex and on the bonding region of the elongate rod and thermally bonding the fastener to the bonding region of the elongate rod while the fastener is positioned in the passageway of the cortex.

Abstract: A hydrostatic bearing spindle device includes: a spindle includes tapered portion having tapered radial receiving surface and flange having first thrust receiving surface and second thrust receiving surface formed at rear side from first thrust receiving surface; first thrust bearing has first thrust bearing surface facing first thrust receiving surface; second thrust bearing has second thrust bearing surface facing second thrust receiving surface; radial bearing facing tapered radial receiving surface; rotation regulator regulates relative rotation of one of first thrust bearing and second thrust bearing with respect to the other; and housing has first screw groove which is screwed with first thrust bearing and second screw groove which is screwed with second thrust bearing. Second screw groove has larger screw pitch than first screw groove does when tapered portion expands rearward, and first screw groove has larger screw pitch than second screw groove does when tapered portion expands frontward.

Abstract: A bit that includes reclaiming a substantially solid body from a consumed conical bit. The substantially solid body includes a truncated forward body portion where the destroyed bit was removed and a generally cylindrical shank portion depending axially from the forward body portion. A new forward portion that includes a generally cylindrical bore or a tapered bore axially extending from a forward end of the forward portion is welded to an interface of the truncated forward body portion of the substantially solid body.

Abstract: A method for producing a rack for a steering gear may involve providing a toothed segment and a shaft segment aligned on a longitudinal axis and connecting the segments by axial joining faces by friction welding at a welding joint. For friction welding, the joining faces may be brought into frictional contact by an initial friction force, the segments may be rotated relative to one another, the joining faces may be mutually compressed by way of a contact pressure force until a predefined joining path has been reached by way of a welding force 10 to 20 times the initial friction force, thermal input friction may be performed by an input force 5 to 12 times the initial friction force, and the segments may be moved toward one another in an axial direction by the predefined joining path. The segments may be held in position without friction.

Abstract: A drive unit with a spindle drive and a spindle-drive drive motor, which comprises a rotor, is characterized in that a spindle of the spindle drive is arranged inside the rotor acting as a spindle nut and comprising a hollow shaft. As a result, a particularly compact construction for the drive unit can be realized, which can serve, in particular, as a linear drive of tool sleeve.

Abstract: A method of fabricating a rack, the method includes: supporting a first rack bar having a first toothed part on a shaft of the first rack bar; supporting a second rack bar having a second toothed part on a shaft of the second rack bar such that an axial center line of the second rack bar coincides with an axial center line of the first rack bar; supporting a joint member between the first and second rack bars such that an axial center line of the joint member coincides with the axial center lines of the first and second rack bars; rotating the joint member about the axial center lines of the first and second rack bars relative to the first and second rack bars; and bringing an end of the first rack bar and an end of the second rack bar into friction pressure welding with the joint member.

Abstract: Provided is an aperture-plate moving mechanism, including: a drive block 308 fixed to an aperture plate 301; a linear motion guide 306 for allowing the drive block to move along an axis while preventing the drive block from moving in other directions; a feed screw 302 laid in a direction of the axis; a nut member 305 having a threaded hole engaged with the feed screw, the nut member being prevented from rotating due to a rotation of the feed screw; and an urging member 309 for pressing the drive block onto the nut member in the direction of the axis. With respect to the direction of the axis, the contact portion of either the drive block or the nut member is a convex surface, while the contact portion of the other member is a concave surface having a larger radius of curvature than the convex surface.

Abstract: Described are deburring tools useful for deburring a friction stir weld, methods of forming a friction stir weld combined with a deburring step, and assemblies such as electronic device enclosures that include a deburred friction stir weld.

Abstract: A method for manufacturing a rack bar includes joining axial end portions of first and second bar members to each other, and forming a power transmission section on the second bar member. The first bar member has a toothed portion. When the second bar member is hollow, the method may further include thickening a wall of a portion of the second bar member along the axial direction so as to be coaxial with the first bar member. When the second bar member has a greater diameter than the first bar member, the method may further include cutting an outside diameter of a portion of the second bar member in the axial direction so as to be coaxial with the first bar member. The power transmission section is formed on the portion of the second bar member where the wall has been thickened and/or the outside diameter has been cut.

Abstract: An oscillation jig includes: an oscillation jig base connected to an oscillation table; a first clamp member provided in the oscillation jig base; a second clamp member located at a position opposed to the first clamp member in an oscillation direction and configured to hold a first metal component together with the first clamp member; a link mechanism provided in the oscillation jig base, composed of a plurality of links connected together, connected to the second clamp member, and caused to extend and contract in the oscillation direction; and a clamp actuator configured to cause the link mechanism to extend and contract in the oscillation direction. When the first clamp member and the second clamp member hold the first metal component, a connection center line connecting connection centers of the respective links is made straight in the oscillation direction.

Abstract: A pressure welding method and a pressure welding device (1) are provided. The pressure welding device (1) includes a plastification device (7), an upsetting device (8) and component mountings (34,35,36,37) for the components (2,3,3?,4) to be welded together and a machine frame (12). The pressure welding device (1) further includes a plurality of machine heads (13,14), each having a component mount (34,35), which machine heads are movably arranged on the machine frame and are connected to respective upsetting drives (22). The machine heads (13,14) and respective upsetting drives (22) can be independently driven. An upsetting head or support head (27), which is preferably secured on the frame, is arranged between the machine heads (13,14).

Abstract: A pressure welding method and to a pressure welding device (1) are provided. The pressure welding device (1) includes a plastification device (7), an upsetting device (8) and component mountings (34, 35, 36, 37) for the components (2, 3, 3?, 4) to be welded together and a machine frame (12). The pressure welding device (1) includes a machine head (13) which is arranged so as to move on the machine frame (12). The machine head (13) includes a rotatable spindle (54) and a component mounting element (34, 35) as well as an associated spindle drive (56). The machine head (13, 14) and the spindle drive (56) are separated from each other on the machine frame (12). A controllable mass decoupling (79) including an axially tolerant coupling (80), is arranged in the drive train (57) between the fixed or moveable spindle drive (56) arranged on the machine frame (12).

Abstract: A method of joining workpieces includes locating first ends of two first workpieces in a moveable part coupling portion. The lengths of the first workpieces are measured. Any difference in length between the first workpieces is determined. Two additional workpieces are located adjacent the first ends of the first workpieces based on the determined difference in length. The first workpieces are connected to the second workpieces.

Abstract: A pressure welding device (1) and a pressure welding method are provided. The pressure welding device (1) includes a plastification unit (5), a positioning and compressing unit (6), a controller (26), and an advance unit (7) for a workpiece (3) and for the process axis (13). The advance unit (7) has an open- or closed-loop controllable hydraulic advance drive (12) that is formed as an open- or closed-loop controllable electro-hydraulic direct drive for the process axis (13).

Abstract: An arc weld stud for fastening a member to a structure with an unthreaded nut includes a weld end having an ignition tip, and a threaded portion defined by a thread configured to form a corresponding counter-thread into a smooth bore of the unthreaded nut, wherein the arc weld stud comprises a material that is harder than the material of the unthreaded nut.

Abstract: To provide a method of friction welding and an apparatus of friction welding in which a length of time for manufacturing one product is reduced as much as possible regardless of the dimension errors of works. The fast forwarding distance Lx1 is calculated for the fast forwarding by using the results of measuring the dimensions of works W1, W2 under the condition of the constant slowly forwarding distance Lx2, Thereby, for the work of a legitimate dimension and even for the work having a dimension smaller than the legitimate dimension, the elongation of the slowly forwarding distance is prevented compared with the work having the longer dimension than the legitimate dimension, and the relative proportion of the fast forwarding distance Lx1 is increased by making shorter the specified slowly forwarding distance.

Abstract: In some a friction welding apparatus includes a vacuum chamber which prevents combustion in a vicinity of a tank, the vacuum chamber formed from a flexible seal between the tank and a housing and a magnetic apparatus that encompasses a perimeter of a damaged area of the tank and a friction welding motor operably coupled to the vacuum chamber.

Abstract: In some implementations of ignition-free welding in at least one fastener is attached to a container that resides within a hazardous environment. The fasteners are then used to secure a fill zone to the container. The chamber then receives a sealing material for the purpose of sealing a leak without having to remove the hazardous material.

Abstract: The present invention provides a method of forming a solid projection having excellent mechanical properties on a metal member without supplying thermal energy from the outside, and a projection-forming device and a metal part having a projection manufactured thereby. The means for solving the problems is characterized in that the means is comprised of the processes of pressing the distal end 13a of the processing jig 13 having the hole-opening and a cavity 13b at the distal end against the surface of the metal member workpiece 111 and rotating the metal member workpiece 111 and the processing jig 13 in the direction relatively counter to the other to generate friction heat causing thereby plastic flow into the cavity through the hole-opening 13b.

Abstract: Tubulars are joined to each other without rotation of the tubulars. A coupling is placed between the aligned tubulars and is supported for rotation or oscillating about its longitudinal axis. The tubulars are clamped in a manner that allows a compressive force to be transmitted to the coupling as the coupling is rotated. An induction device can preheat each connection site before friction welding and/or provide heat as the connection is made and is allowed to cool down. The process can continuously create a string of casing or liner that can be run in or drilled into a wellbore.

Abstract: 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.

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 system and method of joining at least two workpieces together using a friction rivet and a friction rivet cap that are friction stirred together after a cutting tip or cutting feature on the friction rivet cuts through workpieces and is then bonded to the friction rivet cap, and wherein the friction rivet cap may be excluded if the friction rivet includes a hollow in the cutting tip, the hollow being flared after the friction rivets cuts through the workpieces to thereby create an integral rivet cap in the end of the friction rivet.

Abstract: The present invention is directed to a tool for friction stir welding including a base material and a coating layer formed on the base material, wherein the coating layer is formed of two or more layers, and the coating layer as a whole has a thermal permeability of 8000 J/s0.5·m2·K or less, at least one layer of the coating layer includes a hexagonal crystal system and/or an amorphous structure, at least one layer of the coating layer includes a cubic crystal system, and the coating layer has compressive stress.

Abstract: A method for the production of a piston for an internal combustion engine, in which a piston blank is forged, which is subsequently separated into two parts, to form an upper piston part and a lower piston part, after which the lower piston part and the upper piston part are machined and then welded to one another. Subsequently, the piston is finished. During forging of the piston blank, the top of the piston blank is partly given the shape of the underside of the upper piston part, and the underside of the piston blank is given the shape that corresponds to the interior of the lower piston part. After forging of the piston blank and before separation of the upper piston part from the lower piston part, the top of the piston blank is given the finished shape of the underside of the upper piston part by a cutting machining method.

Abstract: A friction-weld interface device for improving a structural strength of an assembly includes a first component having a concave tapered surface. The friction-weld interface also includes a second component having a convex tapered surface that is complementary to and is configured to receive the concave tapered surface of the first component. The assembly is formed by friction welding the concave tapered surface to the convex tapered surface. The friction-weld interface device may be used to assemble an air-intake manifold for an internal combustion engine, wherein the air-intake manifold is at least partially joined by the process of friction welding.

Abstract: The invention relates to a method for shaping pipes with the steps connecting a pipe end with a coupling of a connection device for pipes, in particular a quick connector, through friction welding and controlling the region of formation of the molten mass formed during friction welding. The contamination of the inside of the pipe due to welding beads can be prevented with the aid of the invention.

Abstract: A burring apparatus for a friction welding machine comprises a clamp unit provided at the front end of a horizontal main spindle, for holding work piece W1 coaxial with the main spindle, a clamp unit provided at the front end of a slide movable to and away from the main spindle in the direction of the axis of the main spindle and a doughnut-shaped cutter for shearing off a burr. Work piece W2 is moved forward together with the slide until work piece W2 comes into contact with work piece W1 so that the mated ends of work pieces W1 and W2 are friction welded together to form a joint work piece W. The burr formed on the jointed work piece W is sheared off by the cutter. The jointed work piece W is then liberated from the main spindle.

Abstract: Rotary friction welding apparatus comprising a clamp having a backstop for locating a part to be welded by rotary friction welding and a lateral clamp for applying lateral loads to the part to be welded; and a forge for applying forge pressure to the part to be welded when the part is located in the clamp, the clamp securing the part to be welded through a combination of forge pressure and lateral loads. The clamp has friction elements at the interface of either the lateral clamp and/or the backstop and the part to be welded.

Abstract: 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.

Abstract: 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.

Abstract: A method for producing an integrally bladed rotor, in particular a gas turbine rotor, comprises the following steps:—Providing a blade (12) having a lower blade foot that has a joining surface (18);—Retaining the blade (12) in a retaining unit (20); and—Exciting the blade (12) to oscillate about an axis of rotation. A device for carrying out the method comprises a retaining unit, in which blade (12) can be solidly clamped in place, and an oscillating unit (24) that transmits translational oscillations to the retaining unit in a plane substantially parallel to joining surface (18), and a fixation unit (30) for establishing the axis of rotation.

Abstract: A welding method is 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 welding apparatus is provided for forming a weld joint between first and second elements of a workpiece. The apparatus heats 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 mixer, to remove any dendritic-type weld microstructures introduced into the interface material during heating.

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

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 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: An apparatus for forming a workpiece to a desired, non-planar configuration are provided. At least one friction stir forming tool, having a shoulder and a pin, is used to urge the workpiece to the desired configuration and friction stir form the workpiece. The forming tool can urge the workpiece against a contour surface of a die or a shoulder that is opposite the structural member from the tool. Thus, the forming tool plasticizes a portion of the workpiece and urges the workpiece to the desired configuration. In addition, the material properties of the workpiece can be improved by the friction stir processing.

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: 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: According to one aspect of the present disclosure, a part for an article of equipment includes a fluid conducting first region including a corrosion resistant first material, and a fluid conducting second region including a second material. The first region and the second region are either directly or indirectly joined by solid state welding to form a unitary fluid conducting part. According to another aspect of the present disclosure, a method for replacing at least one fluid conducting part of an article of equipment is disclosed wherein a replacement part is provided that includes a fluid conducting first region including a corrosion resistant first material, and a fluid conducting second region including a second material. The second material is substantially identical to the material of a region of the equipment on which the replacement part is mounted. The first and second regions are either directly or indirectly joined by solid state welding to form a unitary fluid conducting replacement part.

Abstract: A friction stir tool is provided to perform friction stir riveting using a partially consumable pin, wherein the pin includes a cutting edge on a bottom surface thereof, wherein the tool is rotated at a first speed to enable cutting by the pin into a first material that is overlapping a second material, wherein after the pin has cut to a sufficient depth, the rotational speed of the tool is increased to thereby enable plasticization of the consumable pin, the first material, and the second material, wherein the tool is then rapidly decelerated until stopped, enabling diffusion bonding between the pin, the first material and the second material.

Abstract: A plasma arc torch that includes a torch body having a nozzle mounted relative to a composite electrode in the body to define a plasma chamber. The torch body includes a plasma flow path for directing a plasma gas to the plasma chamber in which a plasma arc is formed. The nozzle includes a hollow, body portion and a substantially solid, head portion defining an exit orifice. The composite electrode can be made of a metallic material (e.g., silver) with high thermal conductivity in the forward portion electrode body adjacent the emitting surface, and the aft portion of the electrode body is made of a second low cost, metallic material with good thermal and electrical conductivity. This composite electrode configuration produces an electrode with reduced electrode wear or pitting comparable to a silver electrode, for a price comparable to that of a copper electrode.