System and method for light assisted friction stir processing and welding of metallic and non-metallic materials

An apparatus for use in at least one of a friction stir welding (FSW) and a friction stir processing (FSP) operation, comprising:

• a rotating tool adapted to be plunged into a material susceptible to being softened by heating, the rotating tool further adapted to be advanced along a surface of the material;
• a plurality of diode arrays arranged so as to be laterally offset from one another relative to a path of travel of the rotating tool, each said diode array having at least one light emitting diode, the diode array being supported from the apparatus adjacent the surface of the material and adjacent the rotating tool, and the diode array further being controlled to optically heat a portion of the material using optical energy at least one of prior to, or subsequent to, the material being acted on by the rotating tool;
• and
• the diode arrays being selectively energizable depending on a path of travel of rotating tool to enable a non-straight path of travel of the rotating tool to be at least one of pre-heated or post-heated.

An apparatus for use in a friction stir operation, including FSW and FSP, comprising:

• a control subsystem;
• a rotating tool adapted to be plunged into a material susceptible to being softened by heating with light, the rotating tool further adapted to be advanced along a surface of the material by the control subsystem;
• an optical energy generating subsystem controlled by the control subsystem and supported adjacent the surface of the material, and controlled to heat, using optical energy, a portion of the material as the rotating tool is advanced along the material;
• wherein the optical energy generating subsystem includes first and second laser diode arrays individually controlled by the control subsystem;
• and
• wherein the first and second laser diode arrays are selectively arranged relative to a path of travel of the rotating tool, to perform at least one of pre-heating and post-heating along a non-straight joint line of two portions of the material being joined.