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.

Disclosed is a method for making polystyrene foam which utilizes one or more atmospheric gases, particularly CO.sub.2, as the blowing agent in combination with a polymer processing aid (PPA), typically an ester that is relatively non-volatile at the extrusion temperature range. The blowing agent and the PPA may both be introduced into the molten thermoplastic polystyrene resin or the PPA may be incorporated in the solid source polystyrene resins. The resulting foam will be substantially free of residual blowing agent and dimensionally stable at ambient temperatures.

A method of forming a hybrid component having an axis of rotation includes forming a first substrate having a first interface surface and a first average grain size, forming a second substrate having a second interface surface and a second average grain size different from the first average grain size, and inertia welding the first and second substrates at a junction of the first and second interface surfaces to form a solid-state joint between the first and second substrates.

The present invention relates to tooling and methods for disposing, coating, building up, repairing, or otherwise modifying the surface of a metal substrate using frictional heating and compressive loading of a consumable metal material against the substrate. Embodiments of the invention include friction-based fabrication tooling comprising a non-consumable member with a throat and a consumable member disposed in the throat, wherein the throat is operably configured such that during rotation of the non-consumable member at a selected speed, the throat exerts normal forces on and rotates the consumable member at the selected speed; and comprising means for dispensing the consumable member through the throat and onto a substrate using frictional heating and compressive loading. Embodiments of the invention also include fabrication methods using the tools described herein.

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.

Provided is an electrical steel strip friction stir welding method that is able to inhibit the occurrence of coil joint fractures on a production line caused by deterioration of mechanical properties and shape of the coil joint while maintaining high work efficiency and that is also advantageous in terms of rotating tool durability. In the method, preheated double-sided friction stir welding is performed, diameter D (mm) of shoulders of rotating tools satisfies the relationship of the following Expression (7), and rotation speed RS (r/min) of the rotating tools, the diameter D (mm) of shoulders of the rotating tools, and joining speed JS (mm/min), expressed as RSD.sup.3/JS, satisfy the relationship of the following Expression (8),

4TJD10TJ(7), and

180TJRSD.sup.3/JS1500TJ(8).

The present invention relates to tooling and methods for disposing, coating, building up, repairing, or otherwise modifying the surface of a metal substrate using frictional heating and compressive loading of a consumable metal material against the substrate. Embodiments of the invention include friction-based fabrication tooling comprising a non-consumable member with a throat and a consumable member disposed in the throat, wherein the throat is operably configured such that during rotation of the non-consumable member at a selected speed, the throat exerts normal forces on and rotates the consumable member at the selected speed; and comprising means for dispensing the consumable member through the throat and onto a substrate using frictional heating and compressive loading. Embodiments of the invention also include fabrication methods using the tools described herein.

This joint processing method comprises: a friction stir welding step S2 for forming a joint 7 in a plate 5 by friction stir welding a groove 6 in the plate 5; a cold working step S4 for cold working the joint 7 under cold working conditions such that the grain size in the joint is not more than the grain size of an aluminum alloy in the groove 6 prior to the friction stir welding step S2; and a solution heat treatment step S5 for, subsequent to the cold working step S4, performing solution heat treatment of the plate 5. This joint processing method can suppress enlargement of the grains of the joint formed by friction stir welding.

Disclosed is a method for making polystyrene foam which utilizes one or more atmospheric gases, particularly CO.sub.2, as the blowing agent in combination with a polymer processing aid (PPA), typically an ester that is relatively non-volatile at the extrusion temperature range. The blowing agent and the PPA may both be introduced into the molten thermoplastic polystyrene resin or the PPA may be incorporated in the solid source polystyrene resins. The resulting foam will be substantially free of residual blowing agent and dimensionally stable at ambient temperatures.