Apparatus and method for friction surfacing using a consumable pin tool

A method for friction surfacing one or more metals, metal alloys, or other materials using a friction surfacing apparatus comprising a pin tool holder;

• a non-consumable shoulder having an inside diameter and an outside diameter, the inside diameter terminating at an end wall and includes an angled side wall that forms a substantially frustoconical opening at one end;
• and a consumable pin tool coupled to the pin tool holder, the pin tool at least partially protruding from the end wall of the shoulder, the method comprising:
• rotating the consumable pin tool relative to a workpiece while the consumable pin tool engages the workpiece;
• rotating the non-consumable shoulder relative to the workpiece while the consumable pin tool engages the workpiece;
• and
• maintaining the shoulder at a predetermined distance from the workpiece while traversing the consumable pin tool across the workpiece,
• whereby rotation of the consumable pin tool, in conjunction with a forging load imposed between the consumable pin tool, the non-consumable shoulder, and the workpiece provides a combination of frictional heat and thermo-mechanical working to frictionally heat the consumable pin tool to a temperature below its melting point and deposits pin tool material onto the surface of the workpiece.