Apparatus and method for friction stir welding using filler material

A friction stir welding tool, comprising:

• a body having an upper surface defining an entrance opening and a lower surface;
• a pin having a lower surface defining an exit opening and a side surface, wherein the pin extends from the lower surface of the body;
• and
• a passageway defined by the body and the pin, the passageway extending through the entrance opening to the exit opening and is capable of allowing a filler material to pass therethrough;
• and
• means for dispersing the filler material from the friction stir welding tool.

An apparatus capable of friction stir welding, comprising:

• a friction stir welding tool comprising:
• a body having passageway therethrough through which a filler material may pass;
• and
• a pin extending from a bottom of the body capable of creating friction when rotated against a workpiece to weld the workpiece;
• a spindle capable of rotating the friction stir welding tool, wherein the spindle has a passageway therethrough capable of allowing the filler material to pass therethrough and wherein the passageway through the spindle communicates with the passageway through the body;
• a filler material feeder capable of feeding the filler material, wherein the filler material feeder feeds the filler material into the passageway through the spindle;
• and
• a device capable of holding a workpiece.

An apparatus capable of friction stir welding, comprising:

• a friction stir welding tool comprising:
• a body having an upper surface defining an entrance opening and a lower surface;
• a pin having a lower surface defining an exit opening and a side surface, wherein the pin extends from the lower surface of the body;
• a passageway defined by the body and the pin, the passageway extending from the entrance opening to the exit opening and is capable of allowing a filler material to pass therethrough;
• and
• means for dispersing the filler material from the friction stir welding tool;
• a spindle capable of rotating the friction stir welding tool, wherein the spindle has a passageway therethrough capable of allowing the filler material to pass therethrough and wherein the passageway through the spindle communicates with the passageway through the friction stir welding tool;
• a filler material feeder capable of feeding the filler material, wherein the filler material feeder feeds the filler material into the passageway through the spindle;
• and
• a device capable of holding a workpiece.

A friction stir welding method, comprising:

• applying a frictional heating source to a workpiece to plasticize a volume of the workpiece;
• introducing a filler material into the volume of the workpiece;
• applying the frictional heating source to the filler material to plasticize the filler material;
• and
• incorporating the filler material into the volume of the workpiece.

A friction stir welding method, comprising:

• rotating a friction stir welding tool;
• plunging the friction stir welding tool into a workpiece at a first position;
• plasticizing a portion of the workpiece at the first position by frictional heating induced by the friction stir welding tool;
• feeding a filler material into an interface between the friction stir welding tool and the workpiece;
• plasticizing the filler material by frictional heating induced by the friction stir welding tool;
• and
• incorporating the filler material into the plasticized portion of the workpiece.

An apparatus capable of friction stir welding, comprising:

• means for applying a frictional heating source to a workpiece to plasticize a volume of the workpiece;
• means for introducing a filler material into the volume of the workpiece;
• means for applying the frictional heating source to the filler material to plasticize the filler material;
• and
• means for incorporating the filler material into the volume of the workpiece.

An apparatus capable of friction stir welding, comprising:

• means for rotating a friction stir welding tool;
• means for plunging the friction stir welding tool into a workpiece at a first position;
• means for plasticizing a portion of the workpiece at the first position by frictional heating induced by the friction stir welding tool;
• means for feeding a filler material into an interface between the friction stir welding tool and the workpiece;
• means for plasticizing the filler material by frictional heating induced by the friction stir welding tool, and
• means for incorporating the filler material into the plasticized portion of the workpiece.