A friction stir additive manufacturing device configured to join a first work-piece and a second work-piece is provided. In one aspect, the device includes a rotating spindle configured to deposit a filler material over a weld line as the device is advanced along an interface between the first work-piece and the second work-piece. The device also includes a deposition head configured to receive at least a portion of the spindle, the deposition head configured to remain stationary relative to the rotating spindle. The deposition head includes a first semi-cylindrical portion having an inner radius and an outer radius relative to a first axis, and a second semi-cylindrical portion having an inner radius and an outer radius relative to a second axis that is perpendicular to the first axis. The second semi-cylindrical portion can include a chamfered inner surface configured to define a weld profile.

A thermal energy transfer assembly includes a substrate made of a first material which has a first thermal conductivity coefficient, the substrate having a first surface and a second surface which is opposed to the first surface. The thermal energy transfer assembly also includes a thermal energy transfer element made of a second material having a second thermal conductivity coefficient which is greater than the first thermal conductivity coefficient. The thermal energy transfer element is applied to the first surface using additive friction stir deposition and extends into the substrate toward the second surface. The thermal energy transfer element and the substrate meet together in a stir zone which includes a mixture of both the first material and the second material.

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 device for depositing a material layer on a surface of a workpiece has a deposition facility with a hollow shoulder that is rotatable about an axis relative to a base. The shoulder has an indentation that is limited by a circumferential annular face. A passage opening, which is smaller in diameter than the indentation, is formed in the shoulder along the axis. The shoulder is rotated and a deposition material is fed through the passage opening into the indentation where it is plasticized in the indentation. The deposition facility is moved over the surface in such a way that the indentation points towards the surface and a workpiece plane runs tangentially to the surface at the point at which the axis intersects the surface. The annular face is distanced from the surface such that plasticized deposition material is deposited on the surface. A related deposition method is also provided.

A method for friction stir forming a metal matrix composite (MMC) structure (76). The method includes the step of providing a substrate (12) comprising a metallic material and securing a preformed MMC layer (14, 16) comprising an MMC material in a position overlying at least a portion of the substrate (12). The method further includes the step of friction stirring the preformed MMC layer (14, 16) with a friction stirring tool (50) which includes a rotating probe (56), including locating the probe (56) at a stirring depth at which the probe (56) extends through the preformed MMC layer (14, 16) into a portion of the substrate (12) and passing the tool (50) through the preformed MMC layer (14) at the stirring depth to friction stir the preformed MMC layer (14, 16) and integrate the preformed MMC layer (14, 16) with the substrate (12).

A method of additive manufacturing a part having integrated passages is provided. In one aspect, the method includes forming a part having a near net shape by moving a friction stir tool to deposit a filler material in a predetermined formation. The tool can include a rotating spindle having a channel configured to hold the filler material. The method can include machining the near net shape part to form a plurality of grooves extending into a surface of the part, the plurality of grooves sized and shaped to each receive a tube. The method can include placing a tube into each of the plurality of grooves and moving the tool across the surface of the part and depositing additional material configured to secure the tubes within the plurality of grooves. The method can include machining the additional material deposited over the tubes to a predetermined shape.

Tools for use in solid state manufacturing processes are described. Certain configurations of the tool include multiple different components that can reversibly couple to each other. The tools can be used in solid state manufacturing processes to deposit high strength alloy materials without the need to use a lubricant with the materials to be deposited.

An manufacturing installation for manufacturing a manufactured object by additive friction stir deposition includes a manufacturing system configured to manufacture a manufactured object by additive friction stir deposition from a manufacturing material, and a feed system configured to feed the manufacturing system with manufacturing material. The feed system includes a spool of a manufacturing material wire wound about a spool axis; an unwinding device configured to unwind the wire, to drive the spool in rotation about a principal axis of rotation and to drive the wire in rotation about its neutral fiber; and a device for guiding the unwound wire to the manufacturing system.

A method of additive manufacturing a part having integrated passages is provided. In one aspect, the method includes forming a part having a near net shape by moving a friction stir tool to deposit a filler material in a predetermined formation. The tool can include a rotating spindle having a channel configured to hold the filler material. The method can include machining the near net shape part to form a plurality of grooves extending into a surface of the part, the plurality of grooves sized and shaped to each receive a tube. The method can include placing a tube into each of the plurality of grooves and moving the tool across the surface of the part and depositing additional material configured to secure the tubes within the plurality of grooves. The method can include machining the additional material deposited over the tubes to a predetermined shape.

Various implementations of a system for friction based additive manufacturing include a tool head that includes a central axis, a first end, and a second end opposite and spaced apart from the first end along the central axis. The tool head defines a feed channel that extends between openings defined by the first end and the second end. The opening defined by the second end is offset from the central axis of the tool head. The tool head is configured for rotating about the central axis. The system also includes an actuator that is configured to urge a feed material through the feed channel in a direction from the first end to the second end. The second end of the tool head is configured for being disposed adjacent a substrate onto which the feed material is being friction stir deposited.