# US 10,500,674 B2 · Additive friction-stir fabrication system for forming substrates with ribs > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 10,500,674 B2 - Document ID: US10500674B2 - Status: Granted - Kind: B2 - Application number: 15/829,038 - Filed: 2017-12-01 - Published: 2018-03-29 - Granted: 2019-12-10 - Earliest claimed: 2013-12-18 - Assignees: MELD Manufacturing Corporation - Applicants: Aeroprobe Corporation - Inventors: Kumar Kandasamy; Jeffrey Patrick Schultz - Web page: https://patentgrep.com/patent/US10500674B2 ## CPC - B23K 20/1215: {for other purposes than joining, e.g. built-up welding} - B23K 20/1245: {characterised by the apparatus} - B23K 20/128: {making use of additional material} - B23K 20/129: {specially adapted for particular articles or work} - B23K 20/1295: {Welding studs} - 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 ## Abstract An additive friction stir fabrication method and system is described which may be used to fabricate and join a rib to a metallic substrate or to repair a defect in a metallic substrate through extrusion. The method may be carried out with or without the addition of preformed ribs. One such method involves feeding a friction-stir tool with a consumable filler material such that interaction of the friction-stir tool with the substrate generates plastic deformation at an interface between the friction-stir tool and a metallic substrate to bond the plasticized filler and substrate together and extrude this material through a forming cavity to form a rib joined to the metallic substrate. Further described is a system for fabricating a rib joined to a metallic substrate through extrusion. ## Claims ### Claim 1 A system for fabricating a rib joined to a substrate through extrusion, comprising: a filler material; a friction stir tool; a substrate; and multiple die assemblies each comprising a forming cavity, wherein the multiple die assemblies are arranged together as a geometric grid; wherein the friction stir tool is configured such that the filler material may be fed through the friction stir tool; wherein the friction stir tool is disposed in a position relative to the substrate, and the substrate is disposed in a position relative to the die assembly, such that the friction stir tool may be rotated and translated along a surface of the substrate in a manner to provide for extrusion of the filler material or the substrate into the forming cavity. ### Claim 2 (depends on 1) The system of claim 1, wherein the cavity comprises a preformed rib. ### Claim 3 (depends on 1) The system of claim 1, wherein the filler material and/or the substrate are independently chosen from plastics, homo-polymers, co-polymers, or polymeric materials comprising polyesters, nylons, polyvinyls such as polyvinyl chloride (PVC), polyacrylics, polyethylene terephthalate (PET or PETE), polylactide, polycarbonates, polystyrenes, polyurethanes, and/or polyolefins such as high density polyethylene (HDPE), low density polyethylene (LDPE), polypropylene, composites, mixtures, reinforcement materials, or a metal matrix composite comprising a metal matrix and a ceramic phase, wherein the metal matrix comprises one or more of a metal, a metal alloy, or an intermetallic, and the ceramic phase comprises a ceramic, and independently chosen from metals, metallic materials, metal matrix composites (MMCs), ceramics, ceramic materials, steel, Al, Ni, Cu, Mg, Ti, or Fe, or an alloy, or an alloy comprising one or more of these metals, as well as combinations of any of these materials. ### Claim 4 (depends on 1) The system of claim 1, wherein the filler material takes the form of a powder, pellet, rod, or powdered-filled cylinder. ### Claim 5 (depends on 1) The system of claim 1, wherein the system is configured to provide for formation of a metallurgical, solid state, or mechanical interlocks between deposited filler material and the substrate. ### Claim 6 (depends on 1) The system of claim 1, wherein the system is configured to provide for enhanced corrosion resistance and/or wear resistance of the substrate and/or the rib. ### Claim 7 (depends on 3) The system of claim 3, wherein the substrate is a sheet metal or metal plate. ### Claim 8 (depends on 1) The system of claim 1, wherein the forming cavity has an open end at the bottom of the die assembly. ### Claim 9 (depends on 1) The system of claim 1, wherein the forming cavity has a closed end at the bottom of the die assembly. ### Claim 10 (depends on 2) The system of claim 2, wherein the preformed rib is I-shaped, L-shaped, Y-shaped, or T-shaped. ### Claim 11 (depends on 1) The system of claim 1, wherein each of the multiple die assemblies comprises a preformed rib. ### Claim 12 (depends on 1) The system of claim 1, wherein the geometric grid is hexagonal, circular, square, rectangular, or triangular. ### Claim 13 (depends on 2) The system of claim 2, wherein the preformed rib comprises one or more grooves capable of interlocking the rib to the substrate. ### Claim 14 (depends on 1) The system of claim 1, wherein one of the die assemblies comprises structure capable of providing for one or more ribs having one or more fillets. ### Claim 15 (depends on 1) The system of claim 1, wherein the cavity does not comprise a preformed rib. ### Claim 16 (depends on 1) The system of claim 1, comprising a plurality of substrates, wherein the plurality of substrates are disposed on top of the multiple die assemblies. ### Claim 17 A system comprising: a filler material; a friction stir tool; one or more substrates; a plurality of die assemblies arranged in a geometric grid pattern, each die assembly comprising a forming cavity; wherein the friction stir tool is configured such that the filler material may be fed through the friction stir tool; and wherein the friction stir tool and substrates are disposed in manner such that the friction stir tool may be rotated and translated along a surface of each substrate in a manner to provide for extrusion of filler material or the substrate into each forming cavity such that a rib is formed according to the geometry of the grid pattern of the die assemblies. ### Claim 18 (depends on 17) The system of claim 17, wherein the friction stir tool is configured to deposit the filler material in a manner such that the rib is formed with varying geometry or size. ### Claim 19 (depends on 18) The system of claim 18, wherein the friction stir tool is configured to allow for a deposition rate of the filler material to be adjusted such that the rib is formed with varying height. ### Claim 20 (depends on 17) The system of claim 17, wherein the forming cavity is configured to provide for the formation of multiple ribs. ### Claim 21 (depends on 17) The system of claim 17, wherein the rib has a continuous metallic phase with a discontinuous phase dispersed within.