Some examples include welding a first workpiece to a second workpiece. For instance, the first workpiece may be secured adjacent to the second workpiece. At least one of the first workpiece or the second workpiece includes a channel or a portion of a channel in a respective surface such that a complete channel is presented when the first workpiece and the second workpiece are secured adjacent to each other. A rotating tip of a welding tool is inserted into the complete channel for welding the first workpiece to the second workpiece. A surface burr resulting from the welding is located within the complete channel.

Provided is a method for manufacturing a liquid cooling jacket including a jacket body and a sealing body joined to the jacket body. The method includes steps of: preparing; placing; first primary joining with a rotary tool; and second primary joining with the rotary tool. The rotary tool includes a base end pin and a distal end pin. The distal end pin includes a flat surface and a protrusion protruding from the flat surface. In the first primary joining and the second primary joining, friction stirring is performed in a state where the jacket body and the sealing body are brought in contact with the flat surface of the distal end pin and the base end pin and only the jacket body is brought in contact with a distal end surface of the protrusion.

A technique for joining parts of incompatible metals involves cold spraying a 150-900 micron thick layer of a metal compatible with the second part onto the first part, and friction stir joining the parts by lap welding while keeping a tool of the FSJ tool at least 300 microns away from the first part (less layer) throughout the joining, to avoid damaging the cold spray to first part interface, and formation of intermetallics. Fatigue resistance was tested, with and without a sealant.

In a double-acting friction stir spot welding device or a double-acting friction stir spot welding method, a pin member and a cylindrical shoulder member that rotates around the axis of the pin member are used as rotary tools, and a clamp member that has a cylindrical shape positioned so as to surround the outside of the shoulder member and is configured to press a workpiece from an obverse surface with an annular pressing surface of the distal end is used as a holding jig. The clamp member has an inclined surface that is adjacent to the inner edge portion of the pressing surface and inclined so as to reduce the inner diameter of the clamp member toward the back side as viewed from the pressing surface.

A friction stir spot welding method includes a welding step of forming a build-up portion on a workpiece by friction-stirring the workpiece, using a pin and a shoulder, while pressing a surface of the workpiece with an end face of a clamp, and filling a portion of the workpiece being softened in a chamber portion of the clamp by press-fitting at least one of the pin and the shoulder into a plastic flow portion of the workpiece. and the friction stir spot welding method further includes a pressing step of pressing a surface of at least one of a region of the build-up portion, which is frictionally stirred by the shoulder, and an adjacent region of the build-up portion against the end face of the clamp with the pin and the shoulder retracted into an accommodation space.

The present invention includes a preparation step in which a stepped portion including step bottom and step side surfaces is formed along an edge of a jacket body, a placing step in which a sealing body is placed on the jacket body forming first and second butted sections, and a main joining step in which friction stir welding (FSW) is performed by moving a rotary tool along the first butted section with only a stirring pin of the rotary tool in contact with only the sealing body. During FSW, a central axis of rotation of the rotary tool is tilted towards a central or peripheral side of the jacket body so that the angle of tilt relative to a vertical plane equals the angle the stirring pin's outer circumferential surface makes with the central axis of rotation subtracted by the angle the step side surface makes with a vertical plane.

Pin tool assemblies for friction stir welding and apparatus and methods that include the pin tool assemblies. The pin tool assemblies include an outer member, an inner member, and a stop. The outer member includes an inner surface that defines an elongate internal cavity and an external shoulder that includes an opening to the elongate internal cavity. The inner member includes a welding end, extends at least partially within the elongate internal cavity, and projects from the opening such that the welding end is external the elongate internal cavity. The pin tool assembly is configured to permit motion of the inner member relative to the outer member. The stop defines a plurality of stop configurations. Each of the stop configurations restricts motion of the inner member relative to the outer member in a stop direction to define a corresponding stop distance between the welding end and the external shoulder.

Disclosed herein are systems, methods, and devices for repairing holes in weld seams created by bobbin friction stir welding tools. A hole may be created when a welding tool or, more specifically, a pin of the tool is removed or otherwise extracted from a weld seam created by the tool. The method may involve inserting a plug (e.g., a rivet) into the hole, reshaping the plug in the hole (e.g., riveting) thereby securing the plug in the component, and creating another weld seam through the plug thereby consuming the plug. In some embodiments, the hole may be reshaped prior to inserting the plug. For example, the hole may be drilled out and/or a countersink may be created on one or both ends of the hole. Furthermore, the plug may extend outside of the hole prior to its reshaping and, in some embodiments, even after reshaping.

Disclosed herein are systems, methods, and devices for repairing holes in weld seams created by bobbin friction stir welding tools. A hole may be created when a welding tool or, more specifically, a pin of the tool is removed or otherwise extracted from a weld seam created by the tool. The method may involve inserting a plug (e.g., a rivet) into the hole, reshaping the plug in the hole (e.g., riveting) thereby securing the plug in the component, and creating another weld seam through the plug thereby consuming the plug. In some embodiments, the hole may be reshaped prior to inserting the plug. For example, the hole may be drilled out and/or a countersink may be created on one or both ends of the hole. Furthermore, the plug may extend outside of the hole prior to its reshaping and, in some embodiments, even after reshaping.

A system, apparatus, or method for joining components is provided. The system applies force along an axis, with a friction pin, to a first substrate, such as with a joiner or joining apparatus. The system also frictionally melts a portion of the first substrate adjacent the friction pin by rotating the friction pin about the axis at a first speed within the first substrate. The system also applies force to the second substrate along the axis and frictionally melts a portion of the second substrate adjacent the friction pin by rotating the friction pin at a second speed within the second substrate. The system embeds a portion of the friction pin within the first substrate and the second substrate. In some configurations, the first speed and the second speed are substantially equivalent. In other configurations, the first speed is different from the second speed.