A high-tensile-strength shank assembly includes a shaft assembly. A first distal end is configured to releasably engage a friction plug assembly. A second distal end is configured to releasably engage a friction pull welder assembly.

A joining method includes abutting an end face of a first metal member in a plate shape having a projecting part on the end face on a rear face of a second metal member in a plate shape having a hole that is bored through the second metal member in a plate thickness direction and simultaneously inserting the projecting part into the hole. The method includes inserting a stirring pin of a rotary tool into an abutment portion of a wall of the hole and an outer peripheral surface of the projecting part from a front face side opposite to the rear face of the second metal member. The rotary tool is moved along the abutment portion to join the abutment portion by friction stirring. The abutment portion is joined together with only the stirring pin of the rotary tool being in contact with the first and second metal members.

The present invention provides a joining method including: a butting step in which a rear face of a first metal member having a recessed groove on its front face is butted against an end face of a second metal member to form a butted portion; and a friction stir step in which a stirring pin of a rotary tool is inserted in the recessed groove so as to be relatively moved therealong for joining the butted portion by friction stir. The diameter of the shoulder portion is set to be smaller than a width of the recessed groove, and in the friction stir step, the butted portion is joined by friction stir in a state that the shoulder portion is spaced from a bottom face of the recessed groove while the shoulder portion holds burrs generated from the first metal member.

Embodiments can include a self-reacting friction stir weld (FSW) tool. The device can be configured to be portable and produce full penetration welds in situ. The FSW tool can include a system that cuts out a portion of the structure surrounding a defective portion of the structure. A work-piece can be inserted within the removed portion and friction stir welded to the structure via the FSW tool. A superior repair as compared to merely welding the defect can be achieved by replacing a portion of the structure surrounding the defect as opposed to merely welding the defect (e.g., the crack). A controlled geometric shaped weld beam can be generated for the interface between the work-piece and the structure, which may led to a stronger, more reliable weld.

The present disclosure is directed to a Friction Stir Welding device for welding one or more arcuate work pieces. The device including an arcuate boom, a friction stir welding head, and a saddle operatively coupling the welding head to the arcuate boom for moving the welding head with respect to the arcuate boom. The saddle may be coupled to the arcuate boom via a drive mechanism for moving the saddle, and the welding head that is coupled thereto, with respect to the arcuate boom. The welding head may also be provided with three degrees of freedom with respect to the arcuate boom so that the welding head can rotate, tilt and move linearly with respect to the arcuate boom.

Methods and systems for providing a cold plate assembly include providing a base and a cover. The cover can be fixedly coupled to the base. Each of the base and the cover can include spaced internal ribs, which can form flow paths when the base and cover are fixedly coupled together. The internal ribs of the base and the cover can have spaced tabs that can be fixedly coupled to the other of the base or the cover. The base and the cover may also include spaced external or outer sacrificial ribs.

A method for forming a multilayer structure from a precursor panel having an edge, the method including steps of connecting an attachment member to the precursor panel such that an edge of the attachment member is in alignment with the edge of the precursor panel and applying heat and gas pressure to expand the precursor panel.

The method includes a step of preparing a first member made of a first metal and a second member made of a second metal having a smaller deformation resistance than the first metal, and a step of joining the first member and the second member. The step of joining includes a step of heating the first member and the second member by relatively rotating the first member and the second member, while pressing the first member and the second member against each other, without changing a relative positional relationship therebetween, and a step of cooling the first member and the second member heated, while being pressed against each other. In a first contact surface which is a surface of the first member coming into contact with the second member, a recess is formed so as to include a region intersecting the axis of rotation.

A method for forming a metal matrix composite (MMC) structure includes forming an assembly including at least two blocks of a primary phase material sharing an interface at which a secondary phase material is disposed. The assembly has a length, a width, and a thickness. The method also includes clamping the assembly to at least one of urge the at least two blocks toward each other or maintain the at least two blocks at a predetermined position. Also, the method includes passing a rotating friction-stir pin along the interface from the front edge to the rear edge. The friction-stir pin has a mixing length extending at least the width of the assembly, and passing the friction-stir pin along the length of the assembly disperses the secondary phase material into the primary phase material and welds the at least two blocks together.

A cast part includes a metallic functional region. The functional region extends in a first direction from a first side to a second side of the cast part. The cast part has a surrounding region at least partially surrounding the functional region. The functional region is shaped by a friction-based process. Further disclosed is a piece of equipment, such as an electrical machine which includes a further component and a device for securing the further component against twisting. The device has a connection between the functional region of the cast part and the further component.