Solid state joining using additive friction stir processing

An additive friction stir method for joining substrates, the method comprising:

• providing first and second substrates to be joined;
• providing a forming plate comprising one or more forming cavities;
• placing one or both of the first and second substrates in communication with the forming plate;
• placing the first and second substrates facing each other;
• rotating and translating an additive friction-stir tool relative to one or both of the substrates;
• feeding a filler material through an opening of the additive friction-stir tool while rotating the filler material, pressing the filler material into one or both of the first and second substrates without the opening of the additive friction-stir tool penetrating the first and second substrates;
• while rotating the filler material, pressing the filler material into one or both of the first and second substrates with sufficient pressure to frictionally heat and deform one or both of the first and second substrates with the filler material;
• and
• extruding one or more of the filler material and the first and second substrates into one or more of the forming cavities of the forming plate.

An additive friction stir method for joining substrates, the method comprising:

• providing first and second substrates to be joined;
• providing a forming plate comprising one or more forming cavities;
• placing one or both of the first and second substrates in communication with the forming plate;
• placing the first and second substrates facing one another;
• providing an additive friction-stir tool comprising a throat disposed on an axis of rotation of the tool, which throat comprises an opening for dispensing a filler material, and the tool comprises no pin through which the filler material is dispensed;
• rotating and translating the additive friction-stir tool relative to one or both of the first and second substrates;
• feeding the filler material through the throat of the additive friction-stir tool and dispensing the filler material through the throat opening;
• deforming the filler material and the first and second substrates;
• and
• extruding one or more of the filler material and the first and second substrates into one or more of the forming cavities of the forming plate.