The present invention provides a method of manufacturing composite material, comprising the steps of: coating a thermally conductive composition on a surface portion of a metal material in at least one configuration from among a paste, film, and tape; and friction stirring the metal material, coated with the thermally conductive composition, at least once, and reacting at least a part of the surface portion of the metal material with the thermally conductive composition to form a composite material.

A friction stir welding method is provided that can prevent defective welding due to a shortage of metal. The friction stir welding method welds metal members (1, 2) using a primary joining rotary tool (F) having a stirring pin (F2), and includes steps of: butting in which the metal members (1, 2) are butted with each other at an angle to form a butted portion (J1); buildup welding in which buildup welding is applied along an inner corner of the metal members (1, 2) formed in the butting step to cover the inner corner by a weld metal (M); and inner corner joining in which only the stirring pin (F2) in rotation is inserted in the inner corner to plastically fluidize the weld metal (M) and the metal members (1, 2) for friction stir welding of the butted portion (J1).

An additive friction stir deposition machine and the method of using it. The friction stir deposition machine has a stationary tool with a fixed shoulder and an opening. The fixed shoulder is fixed from rotation with respect to a substate onto which feedstock material is deposited to build a layer. A guide tube holds the feedstock material and is rotatable within the stationary tool. The opening in the stationary shoulder circumscribes the open end of the guide tube. The feedstock material is co-rotatable with the guide tube and rotating the guide tube rotates with the feedstock.

A solid state additive method includes: disposing a round consumable rod in a hollow stirring tool; based on a coating layer height, setting a gap between a bottom surface of the hollow stirring tool and a base surface; driving the hollow stirring tool to rotate at a first rotation speed; driving the consumable rod to rotate at a second rotation speed, where the second rotation speed and the first rotation speed are different in angular speed to form a differential, such that the consumable rod rubs against an inner wall of the hollow stirring tool to generate thermal deformation so as to obtain a plastic deformation flow in the hollow stirring tool; pressing the consumable rod downward to enable the plastic deformation flow to be in friction contact with the base surface; translating the hollow stirring tool and stirring the base surface.

An additive friction stir deposition device is provided. In one aspect, the device includes a shoulder configured to rotate about a central axis. The shoulder includes a channel extending from a first end of the shoulder to a second end of the shoulder. The channel allows a filler material to pass through the shoulder from the first end towards the second end. The shoulder configured to deposit the filler material as the device is advanced along a deposition surface. The device also includes a wire brush skirt configured to co-rotate with the shoulder and contact the deposition surface as the device is advanced along the deposition surface. The device also includes a gas shroud configured to direct pressurized gas toward the deposition surface and remove contaminants as the device is advanced along the deposition surface.

A method of additive manufacturing a structure having integrated passages is provided. In one aspect, the method includes forming first and second parts, each part having a near net shape. The first and second parts are formed by moving a friction stir tool configured to deposit a filler material. An inner surface of each part can be machined to form a generally smooth surface. The first and the second parts are joined to form a structure. The structure is machined to form a generally smooth outer surface. The method includes machining a plurality of grooves extending into the generally smooth outer surface of the structure. A tube is placed into each of the plurality of grooves and a layer of material is deposited to secure the tubes within the plurality of grooves. The method can include machining the outer surface to a predetermined shape.

A method of additive manufacturing a structure having integrated passages is provided. In one aspect, the method includes forming first and second parts, each part having a near net shape. The first and second parts are formed by moving a friction stir tool configured to deposit a filler material. An inner surface of each part can be machined to form a generally smooth surface. The first and the second parts are joined to form a structure. The structure is machined to form a generally smooth outer surface. The method includes machining a plurality of grooves extending into the generally smooth outer surface of the structure. A tube is placed into each of the plurality of grooves and a layer of material is deposited to secure the tubes within the plurality of grooves. The method can include machining the outer surface to a predetermined shape.

A friction stir additive manufacturing system configured to extrude a material is provided. In one aspect, the system includes a spindle configured to rotate about a central axis, the spindle including a conical portion having a plurality of threads at a deposition end of the spindle. The system also includes a housing configured to remain stationary relative to the spindle, the housing including a wire inlet extending through a side wall of the housing, an interior surface of the side wall defining a truncated cone terminating at a material exit, the truncated cone configured to receive the conical portion of the spindle. The system also includes a feeding system configured to feed a wire through the wire inlet and into a gap between the spindle and the truncated cone of the housing.

A friction stir additive welding screw is provided. In one aspect, the friction stir additive welding screw includes a first portion configured to be coupled to a friction stir additive welding device, and a second portion configured to penetrate a work-piece. The second portion includes a plurality of large threads, each large thread extending in a generally longitudinal direction. The second portion also includes a plurality of fine threads positioned along an edge of each large thread, and a plurality of teeth at a tip of second portion.

A friction stir additive manufacturing system is provided. In one aspect, the system includes a spindle configured to rotate about a central axis, and a housing configured to receive at least a portion of the spindle, the housing configured to remain stationary relative to the spindle. The housing includes a wire inlet extending between an exterior surface of the housing and an interior surface of the housing, and a track extending from the wire inlet and partially around a circumference of an interior surface of the housing. The system also includes a feeding system configured to receive a wire from a roller and feed the wire through the wire inlet and into the track of the housing.