Friction stir welding using a superabrasive tool
OwnerTracey W. Nelson, Carl D. Sorensen +2inventors
InventorsTracey W. Nelson, Carl D. Sorensen, Scott Packer, Paul Allen Felter
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Abstract
A probe for friction stir welding MMCs, ferrous alloys, non-ferrous alloys, and superalloys, as well as non-ferrous alloys, the probe including a shank, a shoulder, and a pin disposed through the shoulder and into the shank, wherein the pin and the shoulder at least include a coating comprised of a superabrasive material, the pin and shoulder being designed to reduce stress risers, disposing a collar around a portion of the shoulder and the shank to thereby prevent movement of the shoulder relative to the shank, and incorporating thermal management by providing a thermal flow barrier between the shoulder and the shank, and between the collar and the tool.
Claims50
A friction stir welding tool that is capable of functionally friction stir welding metal matrix composites (MMCs), ferrous alloys, non-ferrous alloys, and superalloys, said friction stir welding tool comprising:
- a friction stir welding tool having a shank, a shoulder and a pin, wherein the shoulder is mechanically locked to the shank to thereby prevent rotational movement of the shoulder relative to the shank;
- a superabrasive material disposed on at least a portion of the shoulder and the pin, wherein the superabrasive material has a first phase and a secondary phase, wherein the superabrasive material is manufactured under an ultra high temperature and an ultra high pressure process;
- at least a second material disposed over the superabrasive coating to thereby contribute properties of the second material to the superabrasive coating;
- and
- wherein the friction stir welding tool is capable of functionally friction stir welding MMCs, ferrous alloys, non-ferrous alloys, and superalloys.
A friction stir welding tool that is capable of friction stir welding metal matrix composites (MMCs), ferrous alloys, non-ferrous alloys, and superalloys, said friction stir welding tool being a monolithic device comprising:
- a shank having a shaft attaching end and a shaft working end;
- a shoulder formed on the shaft working end, the shoulder having a shoulder working edge, wherein the shoulder working edge is formed as a radii;
- a pin formed in the shoulder, wherein the pin is concentric with and parallel to a lengthwise axis of the shoulder from which it extends outwardly, and wherein a first pin radii is formed at a junction between the shoulder and the pin, and a second pin radii is formed at a pin working edge;
- a superabrasive material disposed on at least a portion of the shoulder and the pin, and wherein the friction stir welding tool is capable of functionally friction stir welding MMCs, ferrous alloys, non-ferrous alloys, and superalloys.
A method for friction stir welding metal matrix composites (MMCs), ferrous alloys, non-ferrous alloys, and superalloys, said method comprising the steps of:
- (1) providing a friction stir welding tool having a shank, a shoulder and a pin;
- (2) mechanically locking the shoulder to the shank to thereby prevent rotational movement of the shoulder relative to the shank;
- (3) disposing a superabrasive material on at least a portion of the shoulder and the pin, wherein the superabrasive material has a first phase and a secondary phase, wherein the superabrasive material is manufactured under an ultra high temperature and an ultra high pressure process, and wherein the friction stir welding tool is capable of functionally friction stir welding MMCs, ferrous alloys, non-ferrous alloys, and superalloys;
- and
- (4) inhibiting material from adhering to the friction stir welding tool during the welding process by utilizing a superabrasive material having a low coefficient of friction.
Dependencies are inferred from the claim text.