Thermal stir welder
AssigneeThe United States of America as represented by the Administrator of the National Aeronautics and Space Administration
InventorR. Jeffrey Ding
Life of this patent
Estimating the term…
Abstract
A welding apparatus is provided for forming a weld joint between first and second elements of a workpiece. The apparatus heats the first and second elements to form an interface of material in a plasticized or melted state interface between the elements. The interface material is then allowed to cool to a plasticized state if previously in a melted state. The interface material, while in the plasticized state, is then mixed, for example, using a grinding/extruding mixer, to remove any dendritic-type weld microstructures introduced into the interface material during heating.
Claims17
An apparatus for forming a weld joint between laterally opposed facing edge surfaces of first and second longitudinal elements, said apparatus comprising:
- a support assembly which supports the first and second longitudinal elements as the first and second longitudinal elements are moved longitudinally relative to said support assembly and which holds the laterally opposed facing edge surfaces of the first and second longitudinal elements in abutting relation;
- a heating device which heats at least the laterally opposed facing edge surfaces to a plasticizing temperature as the first and second longitudinal elements are longitudinally moved past said heating device and relative to said support assembly;
- an elongate mixing tool which is mounted downstream of said heating device, which extends into the plasticized facing edge surfaces of the first and second longitudinal elements, and which mixes the plasticized facing edge surfaces thereat as the first and second longitudinal elements are moved past said mixing tool and relative to said support assembly, whereby a longitudinal weld joint is formed between said facing edge surfaces downstream from said mixing tool;
- and
- wherein said support assembly includes first and second containment forging plates respectively positioned on first and second sides of the first and second longitudinal elements so that the first and second longitudinal elements are longitudinally moved between and relative to said forging plates, said containment forging plates a) containing the moving first and second longitudinal elements during mixing by said mixing tool, and b) effecting forging of the moving first and second longitudinal elements downstream of said mixing tool wherein each of said forging plates includes a surface thereof in engagement with a force actuator on respective sides of said first and second longitudinal elements so that the force actuators apply forces to said forging plates to effect forging.
An apparatus for forming a weld joint between laterally opposed first and second facing edge surfaces of respective first and second longitudinal elements made of dissimilar materials, said apparatus comprising:
- a support assembly which supports the first and second longitudinal elements as the first and second longitudinal elements are moved longitudinally relative to said support assembly and which holds the laterally opposed first and second facing edge surfaces of the first and second longitudinal elements in abutting relation;
- a first heat source which heats the first facing edge surface of the first longitudinal element to a plasticizing temperature of the material of the first longitudinal element as the first and second longitudinal elements are longitudinally moved past said first heating device,
- a second heat source separate from said first heat source which heats the second facing edge surface of the second longitudinal element to a plasticizing temperature of the material of the second longitudinal element as the first and second longitudinal elements are longitudinally moved past said second heating device;
- an elongate mixing tool which is mounted downstream of said heating device, which extends into the plasticized first and second facing edge surfaces of the first and second longitudinal elements, and which mixes the plasticized first and second facing edge surfaces thereat as the first and second longitudinal elements are moved past said mixing tool, whereby a longitudinal weld joint of the dissimilar materials is formed between said first and second facing edge surfaces downstream from said mixing tool;
- wherein said support assembly includes first and second containment forging plates respectively positioned on first and second sides of the first and second longitudinal elements so that the first and second longitudinal elements are longitudinally moved between and relative to said forging plates, said containment forging plates a) containing the moving first and second longitudinal elements during mixing by said mixing tool, and b) effecting forging of the moving first and second longitudinal elements downstream of said mixing tool wherein each of said forging plates includes a surface thereof in engagement with a force actuator on respective sides of said first and second longitudinal elements so that the force actuators apply forces to said forging plates to effect forging.
Dependencies are inferred from the claim text.