Described are enclosures that include a friction stir weld, including electronic device enclosures, and precursors thereof, that contain a base and a cover that in an assembled condition form a joint at which a friction stir weld can be produced, as well as methods for producing a friction stir weld at a joint of such an assembly.

A method of friction welding a first component to a second component, the method having the steps of: rotating the first component relative to the second component about a rotation axis; and bringing the first component into contact with the second component; wherein, while the first component and the second component are in contact, a first average force is applied during a first stage of the friction welding process and a second average force is applied during a second stage of the friction welding process; and the second average force is different from the first average force.

A method of joining a first component to a second component at respective connection surfaces, comprising, in order, applying a local surface treatment to the connection surface of at least one of the first and second components in order to locally alter the microstructure to a depth of between 60 m and 10 mm below the connection surface; and joining the first component to the second component using a welding process.

An airfoil for a gas turbine engine according to an example of the present disclosure includes, among other things, an airfoil body defining a recessed region and including at least one rib dimensioned to loop about a respective pocket within a perimeter of the recessed region. At least one cover skin is welded to the airfoil body along the at least one rib to enclose the recessed region. The at least one cover skin is welded to the at least one rib along a respective weld path. The weld path defines a weld width, the at least one rib defines a rib width, and a ratio of the weld width to the rib width is equal to or greater than 3:1 for each position along the weld path. A method of forming a gas turbine engine component is also disclosed.

A method and associated system for joining workpieces formed of neutron absorbing materials. The method includes positioning first and second workpieces together to form a joint, heating the first and second workpieces at the joint to a plastic condition, intermingling plastic material from the first and second workpieces together at the joint, and cooling the intermingled plastic material to a solid state forming a welded fusion zone comprised of material from the first and second metal matrix composite workpieces. The workpiece material at the joint is not melted by the heating. The heating may be performed by frictionally heating the materials with a rotary tool. In one non-limiting embodiment, the neutron absorbing workpieces may be formed of metal matrix composites comprising aluminum or aluminum alloy and boron carbide.

An interlayered structure for joining of dissimilar materials includes: a first material substrate; a second material substrate having a composition dissimilar from a composition of the first material substrate; and a plurality of interlayers disposed between the first material substrate and the second material substrate, including a first interlayer nearest to the first material substrate and a last interlayer nearest to the second material substrate. The first interlayer has a composition selected to have a maximum solid solubility within the composition of the first material substrate that is greater than or equal to the other interlayers within the composition of the first material substrate, and the last interlayer has a composition selected to have a maximum solid solubility within the composition of the second material substrate that is greater than or equal to the other interlayers within the composition of the second material substrate.

A method of friction welding a workpiece to a fluid element includes the step of placing a workpiece weld surface in contact with a fluid element weld surface. The workpiece weld surface is driven in a predetermined pattern along the fluid element weld surface. Pressure is applied between the workpiece weld surface and the fluid element weld surface to produce friction and heat sufficient to raise the temperature of the weld surfaces to welding temperature. A weld bond is formed by stopping the driving of the workpiece weld surface while applying the pressure between the weld surfaces. Before and/or after the weld bond is formed, at least a portion of the workpiece is machined to form at least a portion of a fluid fitting configured to receive and sealingly attach to a pipe in a non-leaking manner to convey a flow of fluid therethrough.

A method for manufacturing a piston of an internal combustion engine from a piston upper part and a piston lower part may include producing at least the piston lower part as a forged steel part. A partial cross section of a cooling duct may be provided in the piston lower part. A closed supply inlet funnel may be forged within the piston lower part. The closed supply inlet funnel may be bored into the piston lower part from the cooling duct. A borehole may be introduced into the piston lower part obliquely to a piston axis. The piston lower part and the piston upper part may be welded to one another.

The invention relates to a device and a method for changing the welding direction of the welding shoulder of a system for a friction stir welding process virtually without delay when required by the geometric arrangement of the joint partners to be welded or by a material unevenness, having the following method features: a) a main part (1) with a horizontally movable bridge support (5) has a friction welding head (12) which can be vertically adjusted together therewith and which has a pin receiving area (13) for mounting and driving a welding pin tip (14), wherein the welding shoulder (18) has a welding shoulder receiving area (17) which is supported at multiple points, and b) the welding shoulder receiving area (17) can be adjusted to any angle of attack relative to the joint partners by means of different push-pull rods (16) during the welding process.

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.