# US 10,118,248 B2 · Method for making a friction stir welding tool

> Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt

- Number: US 10,118,248 B2
- Document ID: US10118248B2
- Status: Granted
- Kind: B2
- Application number: 15/918,849
- Filed: 2018-03-12
- Published: 2018-09-20
- Granted: 2018-11-06
- Earliest claimed: 2017-03-09
- Assignees: King Fahd University of Petroleum and Minerals
- Applicants: King Fahd University of Petroleum and Minerals
- Inventors: Zafar Iqbal; Abdelrahman N. Shuaib; Necar Merah; Nouari Saheb
- Web page: https://patentgrep.com/patent/US10118248B2

## CPC

- B23K 20/1255: {Tools therefor, e.g. characterised by the shape of the probe}
- B22F 9/14: using electric discharge
- C22C 1/1084: {by mechanical alloying (blending, milling)}
- C22C 27/04: Alloys based on tungsten or molybdenum
- C22C 32/0052: {only carbides}
- B22F 9/04: starting from solid material, e.g. by crushing, grinding or milling ({C22C1/1084 takes precedence}; crushing, grinding or milling, in general, see the relevant subclasses, e.g. B02C)
- B22F 2005/002: {Tools other than cutting tools}
- B22F 2009/043: {by ball milling}
- B22F 2998/10: Processes characterised by the sequence of their steps
- B22F 2999/00: Aspects linked to processes or compositions used in powder metallurgy
- B23K 2103/04: Steel {or steel} alloys
- B23K: SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B22F: WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER (making alloys by powder metallurgy C22C); APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- C22C: ALLOYS (treatment of alloys C21D, C22F)

## Abstract

A friction stir welding tool comprising a composite of a tungsten-rhenium alloy and hafnium carbide particles, wherein a crystallite size of the tungsten-rhenium alloy is no more than 100 nm, wherein the hafnium carbide particles are dispersed within the tungsten-rhenium alloy, a method of fabricating the friction stir welding tool, and a method of friction stir welding a metal joint using the tool. Various embodiments of the friction stir welding tool, the method of fabricating the tool, and the method of friction stir welding using the tool are provided.

## Claims

### Claim 1

A method of fabricating a friction stir welding tool having a cylindrical, conical or triangular tip, and a shoulder, comprising:
forming a composite of a ball-milled tungsten-rhenium alloy and hafnium carbide particles, by:
ball-milling a tungsten-rhenium alloy for no more than 25 hours to form a first powder, wherein a concentration of rhenium is in the range of 20 to 30 wt %, relative to the total weight of the tungsten-rhenium alloy;
mixing hafnium carbide particles with the first powder to form a second powder, wherein a concentration of hafnium carbide particles in the second powder is in the range of 1 to 15 vol %, relative to the total volume of the second powder;
ball-milling the second powder for no more than 15 hours to form a third powder; and
spark-plasma-sintering the third powder at a temperature of 1500 to 2000° C. for no more than 10 minutes to form the composite of the ball-milled tungsten-rhenium alloy and hafnium carbide particles, wherein the ball-milled hafnium carbide particles are dispersed within the ball-milled tungsten-rhenium alloy, and wherein the ball-milled tungsten-rhenium alloy has a crystallite size of no more than 100 nm;
coating the composite with a lubricant; and then
extruding the composite to form the friction stir welding tool.

### Claim 2 (depends on 1)

The method of claim 1, wherein a crystallite size of the ball-milled tungsten-rhenium alloy in the third powder is in the range of 10 to 50 nm.

### Claim 3 (depends on 1)

The method of claim 1, wherein the third powder is compacted with a pressure of 40 to 60 MPa during the spark-plasma-sintering.

### Claim 4 (depends on 1)

The method of claim 1, wherein the tungsten-rhenium alloy is ball-milled in an inert atmosphere with a milling speed of 200 to 300 rpm, wherein a ball-to-powder weight ratio is in the range of 6:1 to 10:1.

### Claim 5 (depends on 1)

The method of claim 1, wherein the second powder is ball-milled in an inert atmosphere with a milling speed of 100 to 200 rpm, wherein a ball-to-powder weight ratio is in the range of 4:1 to 6:1.

### Claim 6 (depends on 1)

The method of claim 1, wherein the lubricant is at least one selected from the group consisting of a colloidal graphite, a glass powder, a silica particle, a silicon adhesive and combinations thereof.