A linear friction welding system in one embodiment includes a welding control system operably connected to a hydraulic press and a ram, the welding control system including a processing circuit operably connected to a memory and configured to execute program instructions stored in the memory to bring a shaped charge portion of a first component to be welded into contact with a second component to be welded, and establish an initial scrub load pressure between the two components based upon a ratio between initial surface area of a contact initiation portion of the shaped charge portion and a final surface area of the first component. The processing circuit increases pressure between the components from the initial scrub load pressure to a target scrub load pressure before terminating oscillation of the ram and establishing or maintaining a weld load pressure.

A method of depositing an extrudate onto a substrate, the method including steps of rotating a stirring tool about an axis of rotation while urging a tool distal end of the stirring tool against the substrate, and wherein the stirring tool defines a bore, extending therethrough; positioning a die adjacent to the stirring tool, such that the stirring tool rotates relative to the die; and passing feedstock through the bore toward the tool distal end.

A cam assembly in a linear friction welding system includes two power shafts. Each of the shafts have two timing gears mounted thereupon. For one of the shafts, one of the timing gears includes a slot extending within the timing gear which is formed as an arc about a center of rotation of the power shaft. The other timing gear on that shaft includes a fixed pin which extends into the slot. A cross-over shaft is operably connected to both power shafts.

A method of forming an assembly in which a metal extension element is connected with a metal stub element, by an intermediate element. The intermediate element extends between first and second ends. The intermediate element is positioned to locate its first end spaced apart from the stub element. An inner end of the extension element is spaced apart from the second end of the intermediate element. Heating elements are located between the elements, to heat the proximal portions of the elements to a hot working temperature, at which the heated portions are subject to plastic deformation. The heating elements are removed, and while the intermediate element is rotating, the first end is urged against the stub element to bond the intermediate element with the stub element. While the extension element is rotating, the inner end is urged against the second end to bond the extension element and the intermediate element.

Disclosed is a method of making an integrally bladed rotor. According to the method, a rotor disk comprising a radially outer rim surface is provided. A portion of the disk outer rim surface is removed, leaving a protrusion on the rotor disk outer rim surface. The disk with material removed is subjected to thermal processing. A blade comprising an airfoil and a base is positioned such that a base surface is in contact with the protrusion, and heat, pressure, and motion are applied between the blade and the disk to friction weld the base surface to the protrusion.

Apparatus for providing thermal energy to an article, the apparatus comprising: a first flexible heater configured to emit infrared radiation; and a first flexible member comprising a material configured to absorb the infrared radiation emitted by the first flexible heater and to generate thermal energy from the absorbed infrared radiation, the first flexible member being configured to transfer the generated thermal energy to the article through thermal conduction.

A linear friction welding machine comprising a compression unit and an oscillator unit, each having a clamping holder for a workpiece. Both clamping holders are configured such that workpieces are held with the surfaces thereof to be welded, aligned and facing each other. The clamping holder of the compression unit is linearly movable relative to the clamping holder of the oscillator unit, and the latter is movable in an oscillating manner at right angles transversely with respect to the direction of travel of the compression unit and fixed to ends of vertical and horizontal supports which can be deflected laterally in a sprung manner in the oscillation direction, the other ends of which are anchored rigidly on supporting bodies. The supports are flexible under deflection in the oscillation direction but are designed to resist buckling when the clamping holders are loaded in the direction of travel of the compression unit.

A linear friction welding system in one embodiment includes a ram configured to oscillate along a welding axis, and a first and second power shaft operably connectable to the ram through a vibrating assembly. Respective motors are configured to drive respective power timing gears fixedly connected to the first and second power shafts. A slave timing gear is operably connected to the first power shaft in variable rotational relationship and to the second power shaft in fixed rotational relationship. The first slave timing gear is configured to be driven by one power shaft to force oscillation of the ram and by the other power shaft to stop oscillation of the ram.

According to the invention, a blade is friction-welded to a rotor disk of a turbomachine, the disk comprising a projecting block having an outer surface to which the blade is to be welded. To this end: a surfacing process is carried out on at least a part of the periphery of the block, in the region of said outer surface; the outer surface of the block and the surfacing are machined in order to level same; and friction-welding is then carried out between the surfaced outer surface of the block and the blade.

An additive manufacturing system (110) for depositing an extrudate (112) onto a substrate (114) comprises a deposition head (116). The deposition head (116) comprises a stirring tool (118), rotatable about an axis of rotation AR and comprising a tool distal end (120) and a tool proximal end (122), axially opposing the tool distal end (120) along the axis of rotation A.sub.R. The stirring tool (118) defines a bore (124), extending from the tool proximal end (122) to the tool distal end (120). The bore (124) is configured to receive feedstock (126), biased toward the tool distal end (120). The deposition head (116) also comprises a die (128), which is positioned adjacent to the stirring tool (118), defines a die axis A.sub.D1, and comprises a die distal end (130) and a die proximal end (132), axially opposing the die distal end (130) along the die axis A.sub.D1, and wherein the die axis A.sub.D1 is parallel with the axis of rotation A.sub.R of the stirring tool (118).