# US 2014/0151438 A1 · Apparatus to join tubulars using friction stir joining > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2014/0151438 A1 - Document ID: US20140151438A1 - Status: Published application - Kind: A1 - Application number: 13/894,250 - Filed: 2013-05-14 - Published: 2014-06-05 - Earliest claimed: 2012-05-14 - Inventors: Rodney Dale Fleck; Bonnie Powell; Paul T. Higgins; Rod W. Shampine; Russell J. Steel; Scott M. Packer; Edward K. Leugemors; Timothy M. Lesko - Web page: https://patentgrep.com/patent/US20140151438A1 ## CPC - B23K 20/1225: {Particular aspects of welding with a non-consumable tool} - B23K 20/122: {using a non-consumable tool, e.g. friction stir welding} - B23K 20/123: {Controlling or monitoring the welding process} - B23K 20/126: {Workpiece support, i.e. backing or clamping} - B23K 37/0531: Internal pipe alignment clamps - B23K 2103/10: Aluminium or alloys thereof - 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 A system and method for repairing and/or joining together multiple lengths of tubulars using friction stir joining, and a system for manipulating the tubular so that friction stir joining may be performed while the tubular is on a reel and/or at a field site. ## Claims ### Claim 1 A system comprising: a fixture machine to hold and align a first end of a first tubular and a second end of a second tubular; a mandrel disposed inside the first and second tubular to provide a reactive force during friction stir joining; and a friction stir joining machine for performing friction stir joining of the first and second ends of the first and second tubulars. ### Claim 2 (depends on 1) The system as defined in claim 1 wherein the fixture machine and the friction stir joining machine are integrated into a single portable system. ### Claim 3 (depends on 1) The system as defined in claim 1 wherein the fixture machine further comprises clamps for manipulating the tubular in a Z axis, W axis, and/or Y and/or X axis and U axis, or any combination of axis movements. ### Claim 4 (depends on 1) The system as defined in claim 1 wherein the fixture machine further comprises clamps for elastically or plastically deforming the tubular. ### Claim 5 (depends on 1) The system as defined in claim 1 wherein the fixture machine further comprises at least four independently controllable clamps for deforming the tubular. ### Claim 6 (depends on 1) The system as defined in claim 1 wherein the friction stir joining machine further comprises a friction stir joining tool that rotates around the tubular while the tubular is held stationary by the fixture machine. ### Claim 7 (depends on 1) The system as defined in claim 1 wherein the fixture machine includes temperature control means for changing a temperature of the tubular. ### Claim 8 (depends on 1) The system as defined in claim 1 wherein the system further comprises a roller for manipulating residual or compressive stresses in the joint of the tubular. ### Claim 9 (depends on 1) The system as defined in claim 1 wherein the fixture machine further comprises a post processing system for performing finishing on the tubular. ### Claim 10 (depends on 1) The system as defined in claim 1 wherein the fixture machine further comprises testing equipment for performing one or more nondestructive tests of the tubular. ### Claim 11 (depends on 1) The system as defined in claim 1 wherein the fixture machine further comprises testing equipment that can perform non-destructive tests from the group of non-destructive tests comprised of: hydrostatic internal testing, hydrostatic external testing, ultrasonic inspection, magnetic flux leakage inspection, X-ray inspection, gamma ray inspection, and positron decay inspection. ### Claim 12 (depends on 1) The system as defined in claim 1 wherein the friction stir joining machine further comprises the ability to perform friction stir processing. ### Claim 13 (depends on 1) The system as defined in claim 1 wherein the mandrel further comprises a disposable mandrel. ### Claim 14 (depends on 1) The system as defined in claim 1 wherein the mandrel further comprises a reusable mandrel. ### Claim 15 (depends on 1) The system as defined in claim 1 wherein the mandrel further comprises a partially disposable mandrel and a partially reusable mandrel. ### Claim 16 (depends on 1) The system as defined in claim 1 wherein the mandrel further comprises: a hard mandrel portion that provides support for friction stir joining; and a supporting mandrel portion that is at least partially dissolvable. ### Claim 17 (depends on 16) The system as defined in claim 16 wherein the hard mandrel portion is comprised of a plurality of hard mandrel segments. ### Claim 18 A method for performing friction stir joining of tubular, and comprising: 1) clamping two ends of a tubular in a fixture machine; 2) inserting a mandrel in the tubular along a joint formed by the two ends of the tubular; 3) aligning the two ends of the tubular; and 4) friction stir joining the two ends of the tubular along the joint using a friction stir joining tool. ### Claim 19 (depends on 18) The method as defined in claim 18 wherein the method further comprises using a mandrel that is at least partially dissolvable. ### Claim 20 (depends on 18) The method as defined in claim 18 wherein the method further comprises using a mandrel that is at least partially reusable. ### Claim 21 (depends on 18) The method as defined in claim 18 wherein the method further comprises using a mandrel that is at least partially reusable and at least partially dissolvable. ### Claim 22 (depends on 18) The method as defined in claim 18 wherein the method further comprises removing the mandrel from the tubular by dissolving at least a portion of the mandrel. ### Claim 23 (depends on 18) The method as defined in claim 18 wherein the method further comprises disposing a fluid in the coiled tubing that will cause at least a portion of the mandrel to dissolve. ### Claim 24 (depends on 18) The method as defined in claim 18 wherein the method further comprises providing a plurality of hard mandrel segments on the disposable mandrel that react the forces of friction stir joining, and which flow through the coiled tubing after at least a portion of the disposable mandrel is dissolved. ### Claim 25 (depends on 24) The method as defined in claim 24 wherein the method is further comprised of: 1) forming the joint such that the joint in the tubular is along a bias; and 2) placing a plurality of hard mandrel segments of the mandrel along the bias in the tubular. ### Claim 26 (depends on 18) The method as defined in claim 18 wherein the method is further comprised of sending a projectile through the tubular to thereby remove the mandrel. ### Claim 27 (depends on 18) The method as defined in claim 18 wherein the method further comprises elastically or plastically deforming the tubular by using the clamps. ### Claim 28 (depends on 18) The method as defined in claim 18 wherein the method further comprises independently controlling the clamps in order to elastically or plastically deforming the tubular. ### Claim 29 (depends on 18) The method as defined in claim 18 wherein the method further comprises rotating the friction stir joining tool around the tubular while the tubular is held stationary by the clamps. ### Claim 30 (depends on 18) The method as defined in claim 18 wherein the method further comprises joining together two ends of coiled tubing from different reels of coiled tubing to thereby increase a total length of the tubular. ### Claim 31 (depends on 18) The method as defined in claim 18 wherein the method further comprised of preparing the two ends of the tubular for friction stir joining by using the fixture machine to perform procedures from the group of procedures including: reaming, facing, surface preparation of the ends of the tubing to be joined, resizing (i.e. swaging), and making the coiled tubing a desired cross-sectional shape. ### Claim 32 (depends on 18) The method as defined in claim 18 wherein the method further comprises performing the friction stir joining of the coiled tubing at a field location that is not the place of manufacturing of the coiled tubing. ### Claim 33 (depends on 18) The method as defined in claim 18 wherein the method further comprises testing of the joint using at least one non-destructive test. ### Claim 34 A method for repairing a non-compliant tubular comprising: 1) removing a portion of the tubular to form at least a first end of a first tubular; 2) aligning the first end of the first tubular with a second end of a second tubular; 3) disposing a mandrel within the first and second tubular along the first and second ends; and 4) performing friction stir joining of the first and second ends to form a FSJ joint. ### Claim 35 (depends on 34) The method as defined in claim 34, wherein the first and second tubular are formed from the non-compliant tubular. ### Claim 36 (depends on 34) The method as defined in claim 34, wherein in the mandrel is a disposable mandrel. ### Claim 37 (depends on 34) The method as defined in claim 34, wherein the tubular is coiled tubing. ### Claim 38 (depends on 34) The method as defined in claim 34, wherein the method further comprises testing the integrity of the FSJ joint. ### Claim 39 (depends on 34) The method as defined in claim 34, wherein the method further comprises post processing the FSJ joint. ### Claim 40 (depends on 34) The method as defined in claim 34, wherein the method further comprises identifying a non-compliant section of the tubular. ### Claim 41 (depends on 34) The method as defined in claim 34, wherein the method further comprises inserting at least one plug within the first or second tubular. ### Claim 42 (depends on 34) The method as defined in claim 34, wherein the method further comprises placing a first plug within the first tubular and placing a second plug within the second tubular. ### Claim 43 (depends on 42) The method defined in claim 42, wherein the plug is removable.