Portable friction forge welder

A system for welding a first workpiece to a second workpiece using a portable friction forge welder, comprising:

• a linear actuator for forcibly positioning the first workpiece against the second workpiece by applying a predetermined axial force to the first workpiece;
• a rotational actuator for rotating the first workpiece at a predetermined angular velocity for a forgeable time period to ensure a satisfactory friction forge weld at an interface between the first workpiece and the second workpiece, the forgeable time period beginning as the predetermined axial force is applied;
• and
• means for stopping the rotating at the end of the forgeable time period and maintaining the predetermined axial force until the interface between the first workpiece and the second workpiece has cooled to form a friction forge weld.

A method for portable friction forge welding a first workpiece to a second workpiece, comprising the steps of:

• positionally fixing the first workpiece into close proximity to the second workpiece by a clamping means;
• preloading the clamping means by forcibly positioning the first workpiece against the second workpiece by applying a predetermined constant axial force to the first workpiece by a linear actuator;
• eliminating affects of mechanical flexing of the clamping means by positionally fixing an accurate positional relationship between the first workpiece and the second workpiece while the predetermined constant axial force is applied to the first workpiece;
• rotating the first workpiece by a rotational actuator at a predetermined angular velocity for a forgeable time period to ensure a satisfactory friction forge weld at an interface between the first workpiece and the second workpiece, the forgeable time period beginning as the predetermined axial force is applied;
• stopping the rotating at the end of the forgeable time period;
• and
• maintaining the predetermined axial force until the interface between the first workpiece and the second workpiece has cooled to form a friction forge weld.