A method of operating a linear friction welding apparatus includes supporting a first work piece with a first fixture, supporting a second work piece with a second fixture, establishing a load between the first work piece and the second work piece along a press axis with a press assembly while the first fixture and the second fixture are in a fixed position relative to one another, simultaneously moving, with a vibrating assembly spaced apart from the press axis, the first fixture and the second fixture along a single weld axis so that both the first work piece and the second work piece are moved with respect to one another along the single weld axis after establishing the load, and heating at least a portion of the first work piece while simultaneously moving the first fixture and the second fixture under the load.

The present invention relates to tooling and methods for disposing, coating, building up, repairing, or otherwise modifying the surface of a metal substrate using frictional heating and compressive loading of a consumable metal material against the substrate. Embodiments of the invention include friction-based fabrication tooling comprising a non-consumable member with a throat and a consumable member disposed in the throat, wherein the throat is operably configured such that during rotation of the non-consumable member at a selected speed, the throat exerts normal forces on and rotates the consumable member at the selected speed; and comprising means for dispensing the consumable member through the throat and onto a substrate using frictional heating and compressive loading. Embodiments of the invention also include fabrication methods using the tools described herein.

A workpiece for use with a friction welding process comprises a weld surface. The weld surface comprises a central ridge surface extending along the weld surface, with the central ridge surface being flanked on either side respectively by a first pyramidal surface and a second pyramidal surface. The first pyramidal surface subtends a first pyramidal angle with the central ridge surface, and the second pyramidal surface subtends a second pyramidal angle with the central ridge surface. The first pyramidal surface is further flanked by a third pyramidal surface, and the second pyramidal surface is further flanked by a fourth pyramidal surface, with the third pyramidal surface subtending a third pyramidal angle with the central ridge surface, and the fourth pyramidal surface subtending a fourth pyramidal angle with the central ridge surface. Each of the third pyramidal angle and the fourth pyramidal angle is less than 90.

A deposition apparatus for processing substrates includes a vacuum chamber including a processing zone in which a substrate may be processed. A showerhead assembly includes a stem, face plate and back plate wherein the stem is rotary friction welded to the back plate. A substrate pedestal assembly is configured to support a substrate on an upper surface thereof when a substrate is processed in the deposition apparatus.

A method of fabricating a track link comprises creating a rail portion of a track link from a high alloy steel, creating a main body portion of a track link from a low alloy steel, and friction adhering the rail portion onto the main body portion.

A method of friction welding an airfoil (32) onto a rotor disk of a turbine engine, the disk having at its outer periphery a projecting stub (18) onto which the airfoil is to be welded, the method comprising a step consisting in mounting chocks (24) on leading and trailing edges of the stub, the method being characterized in that, before friction welding, the chocks are secured to the stub by welding, and in that during the friction welding operation, the beads of welding (28) between the chocks and the stub are expelled, at least in part, in seams of material (34) that form around the connection zone between the airfoil and the stub and that are subsequently to be removed or eliminated, e.g. by machining.

A method of operating a linear friction welding apparatus includes supporting a first work piece with a first fixture, supporting a second work piece with a second fixture, establishing a load between the first work piece and the second work piece along a press axis with a press assembly while the first fixture and the second fixture are in a fixed position relative to one another, simultaneously moving, with a vibrating assembly spaced apart from the press axis, the first fixture and the second fixture along a single weld axis so that both the first work piece and the second work piece are moved with respect to one another along the single weld axis after establishing the load, and heating at least a portion of the first work piece while simultaneously moving the first fixture and the second fixture under the load.

The present invention relates to tooling and methods for disposing, coating, building up, repairing, or otherwise modifying the surface of a metal substrate using frictional heating and compressive loading of a consumable metal material against the substrate. Embodiments of the invention include friction-based fabrication tooling comprising a non-consumable member with a throat and a consumable member disposed in the throat, wherein the throat is operably configured such that during rotation of the non-consumable member at a selected speed, the throat exerts normal forces on and rotates the consumable member at the selected speed; and comprising means for dispensing the consumable member through the throat and onto a substrate using frictional heating and compressive loading. Embodiments of the invention also include fabrication methods using the tools described herein.

An example method of attaching an airfoil for an integrally bladed rotor includes placing a support collar in an installed position around at least a leading edge and trailing edge of an airfoil stub to be repaired in an integrally bladed rotor. The support collar and the airfoil stub together have a midline that is positioned between opposing, laterally outer surfaces of the airfoil stub when the support collar is in the installed position. The method performs linear friction welding to add a replacement airfoil to the airfoil stub.

A method of making a bladed rotor for a turbomachine, in particular for an aircraft engine, is disclosed. The method comprises the steps a) providing a rotor base of the rotor, b) providing at least one blade root, c) providing at least one blade body, d) making at least one blade by connecting the blade body to the blade root by means of a diffusion barrier layer, at least the blade body, the diffusion barrier layer and the blade root consisting of respectively different materials, and e) joining the at least one blade root to the rotor base. The invention furthermore relates to a bladed rotor and to a turbomachine having such a bladed rotor.