A method for loading feedstock bars into an additive friction stir deposition machine (AFSD) is described. The method comprises containing a plurality of feedstock bars in a container disposed adjacent to a spindle of the additive friction stir deposition machine. The method further comprises moving one feedstock bar of the plurality of feedstock bars into axial alignment with the spindle of the additive friction stir deposition machine.

Embodiments of the present invention relates to an apparatus (1) for friction stir spot welding and a method of friction stir spot welding providing a keyhole free welding. The method comprises placing an intermediate piece (5) between at least one first workpiece (3) and at least one second workpiece (4) for forming a sandwich structure (S); pressing the sandwich structure (S) such that the intermediate piece (5) is trapped between the second workpiece (4) and an embossing (E) formed on the first workpiece (3); pressing the embossing (E) by a rotating tool comprising a substantially flat end (6.1) for pressing so as to plasticize the intermediate piece (5), at least one part of each of the first workpiece (3) and the second workpiece (4).

A friction stir welding method is provided that can prevent defective welding due to a shortage of metal. The friction stir welding method welds metal members (1, 2) using a primary joining rotary tool (F) having a stirring pin (F2), and includes steps of: butting in which the metal members (1, 2) are butted with each other at an angle to form a butted portion (J1); buildup welding in which buildup welding is applied along an inner corner of the metal members (1, 2) formed in the butting step to cover the inner corner by a weld metal (M); and inner corner joining in which only the stirring pin (F2) in rotation is inserted in the inner corner to plastically fluidize the weld metal (M) and the metal members (1, 2) for friction stir welding of the butted portion (J1).

A method is provided for manufacturing an article. The method comprises depositing by additive friction stir deposition a wear-resistant material on a surface of a preform to provide an intermediate article. The preform comprises a first composition and the wear-resistant material comprises a second composition. The second composition is substantially different from the first composition. The method also comprises machining the intermediate article to remove therefrom at least a portion of the wear-resistant material.

A technique for creating a weld along a joint. A method begins by positioning a first edge of a first member proximate to a second edge of a second member to form the joint, wherein the joint is to be welded along the length from a first position on the joint to a second position on the joint. A clamping ring of a refill spot welding apparatus is placed to surround an unwelded portion of the length. The clamping ring contacts a top surface of the first member and a top surface of the second member. A first refill spot weld process is performed with the refill spot welding apparatus to join the first member and the second member at a first spot weld on the joint.

A component, which may be an automotive chassis structure, includes first and second sub-part main bodies. The first sub-part main body is formed of a first material, and the second sub-part main body is formed of a second material. The first material is a steel alloy, and the second material is aluminum or an aluminum alloy. A transition layer is attached to and contacts the first sub-part main body. The transition layer is formed of a third material, where the third material contains at least a majority of copper. A mixed layer is disposed between the transition layer and the second sub-part main body, and the mixed layer is formed of a mixture of the second material and the third material. A disclosed method includes forming the component by friction stir welding the transition layer to the second sub-part main body.

A component is formed by welding a plurality of sheets of metal to form a blank with a number of weld nuggets, placing the blank between a die section and a lid section, heating the die section to heat the blank, and introducing a pressurized gas between the lid section and the die section to press the blank into a mold in the die section to form a component. The number of weld nuggets has a desired thickness ratio between about 1.1 to about 1.25 such that the plurality of sheets of metal and the component formed have a number of characteristics that are substantially the same.

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.

An extrusion and bonding tool for carrying out a hybrid metal extrusion and bonding process, the tool being for extruding an extrusion material and bonding the extrusion material to a substrate is provided. The tool may comprise a main body and a rotating die through which the extrusion material is extruded, wherein the rotating die moves relative to the main body of the tool, and wherein the extrusion material, in use, is extruded through the rotating die at a position that can vary about a circumferential path about a rotation axis of the tool. The tool may comprise an extrusion chamber; and a plurality of dies through which the extrusion material is extruded associated with the extrusion chamber, wherein the tool is arranged so that, in use, the extrusion material is received in the extrusion chamber and plasticised within the extrusion chamber before being extruded through one of the dies onto the substrate.

A solid-state additive manufacturing additive manufacturing system applicable to building up 3D structures, coating and functionalizing surfaces, joining structures, adding customized features to objects, compounding proprietary compositions and repairing various structures is disclosed. The solid-state additive manufacturing system enables deposition of different fillers, viz. metals, metal alloys, MMCs, polymers, plastics, composites, hybrids and gradient compositions, as well as controls the resulting deposit structures, e.g. specific nano-/micro-, gradient- and porous-material structures. The system accommodates various feeding-, spindle- and tool-designs for depositing different forms of filler materials, viz. rods, wires, granules, powders, powder-filled-tubes, scrap pieces or their combination, and a working platform with multiple access points. One or multiple motors, driving and monitoring units control the movement of the workpiece, spindle and tool and move the filler through the feeding system, which passageway is in communication with the passageways of the spindle and the tool.