Metal fusion bonding – Process – Using dynamic frictional energy
Reexamination Certificate
1999-03-02
2001-06-19
Dunn, Tom (Department: 1725)
Metal fusion bonding
Process
Using dynamic frictional energy
C228S002100
Reexamination Certificate
active
06247633
ABSTRACT:
TECHNICAL FIELD
This invention relates to friction stir welding, and more particularly to a method for creating welded lapped joints using a rotating pin for friction stir welding.
DESCRIPTION OF THE PRIOR ART
Heretofore, friction stir welding has been used to join members at seams that are not overlapped, due to the anticipated limitation of pin extension that is needed to stir the joint material. To ensure a sound butt weld, the depth of pin penetration had to be controlled within a very close tolerance, such as within 0.002 inches of the bottom of the faying surface to ensure a sound weld, and the thickness of the joint had to be constant for the weld tool to work properly.
In an attempt to extend stir welding to lapped joints, the prior art used through-blade penetration that reciprocatingly cut through both members of a lapped joint leaving a thin line of stirred material which was not strong in shear. Such through-penetration is disadvantageous because it does not provide for effective stirring of the material utilizing reciprocation of a blade tool rather than a rotary tool.
As a result, the accepted state of the art for lapped joints continues to use arc welding which, unfortunately, results in high distortion and low strength for lapped joint construction.
SUMMARY OF THE INVENTION
It is an object of this invention to provide a method that enables friction stir welding to be used for lapped joints and thereby provide a low distortion construction which is strong in shear.
A first aspect of the invention that meets the above object is a method of making a low distortion frame construction, the construction having joint regions formed by first and second overlapping members defining a lapped interface, the joint regions being comprised of material that can be converted to a solid state deformable plastic condition by friction heat, comprising: (a) providing a stir friction welding tool having (i) a rotatable thermally conductive body presenting a shoulder to engage the joint region for storing friction-generated heat, and (ii) a friction generating pin rotatable with said body about a pin axis and selectively extendable from the shoulder to progressively penetrate the overlapping members as the joint region in contact with the pin becomes plastic; (b) placing the tool shoulder against the joint region with the pin axis transverse to the lapped interface and spinning the body while progressively extending the pin at a rotational speed effective to generate friction heat that converts the adjacent material of the joint to a plastic condition allowing the spinning of the probe to stir such plastically converted material; and (c) controlling the depth of penetration of the spinning probe while translating the tool across the joint region to perfect a friction stirred welded zone that extends through the interface and between the overlapping members to provide a welded joint that is exceptionally strong in shear.
The interface can be flat or curved such as in lap welding of extruded or hydroformed hollow struts with cast aluminum nodes that fit within the ends of the struts. Preferably, the lapped joint material is aluminum or magnesium alloys, but can be ferrous materials or any material that can be converted to a solid state deformable plastic condition.
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Oros Alvin Kenneth
Ward Susan Marie
White Dawn Roberta
Dunn Tom
Ford Global Technologies Inc.
Malleck Joseph W.
Stoner Kiley
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