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.

An additive manufacturing method for performing additive manufacturing of a metallic powder material on a surface of a metallic base material includes a step of supplying the powder material onto the surface of the base material, a step of welding the powder material to the surface in an unmelted state through friction stir of the powder material and the surface, a step of supplying the powder material onto a welded portion formed by welding the powder material to the surface, and a step of welding the powder material to the welded portion in the unmelted state through friction stir of the powder material and the welded portion.

A rotating tool system attachment on the spindle of a computer numerical control (CNC) machine includes a rotating assembly mounted on a static assembly. The rotating assembly provides a continuous supply of a wire material for deposition on a substrate during an additive manufacturing process. The rotating assembly includes a material supply housing a feedstock of wire mounted on a rotating spindle and a wire feeder configured to draw the wire from the wire supply and provide the wire for application during the additive manufacturing process. The tool system can be attached to the spindle of CNC machine to provide additive manufacturing capabilities to the CNC machine.

The present invention is directed to friction stir welding, and in particular to apparatuses, methods, and systems using friction stir welding to join one or more components comprising an aluminum 2xxx alloy with one or more components comprising an aluminum 7xxx alloy. The aluminum 2xxx alloy may be in the form of a filler insert, for example a sheet or strip, between two larger aluminum 7xxx alloy components, or the aluminum 2xxx alloy may be in the form of a larger component welded directly to an aluminum 7xxx alloy component of comparable size. Weldments according to the present invention have improved resistance to stress corrosion cracking without the need for post-weld artificial aging and are useful in many applications, for example in construction of spacecraft parts.

An additive manufacturing system (110) for depositing an extrudate (112) onto a substrate (114) comprises a deposition head (116). The deposition head (116) comprises a stirring tool (118), rotatable about an axis of rotation AR and comprising a tool distal end (120) and a tool proximal end (122), axially opposing the tool distal end (120) along the axis of rotation A.sub.R. The stirring tool (118) defines a bore (124), extending from the tool proximal end (122) to the tool distal end (120). The bore (124) is configured to receive feedstock (126), biased toward the tool distal end (120). The deposition head (116) also comprises a die (128), which is positioned adjacent to the stirring tool (118), defines a die axis A.sub.D1, and comprises a die distal end (130) and a die proximal end (132), axially opposing the die distal end (130) along the die axis A.sub.D1, and wherein the die axis A.sub.D1 is parallel with the axis of rotation A.sub.R of the stirring tool (118).

The disclosed friction bit joining systems may include a ball screw having an internal bore, a chuck and spindle configured to be rotated by a chuck spindle motor, a friction bit joining bit held by the chuck, a support frame, and a chuck driver motor positioned and configure to rotate the ball screw to axially move the chuck and the friction bit joining bit relative to the support frame. At least a portion of the spindle may be positioned within the internal bore of the ball screw. Various other related systems and methods are also disclosed.

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 method for joining materials using additive friction stir techniques is provided. The method joins a material to a substrate, especially where the material to be joined and the substrate are dissimilar metals. One such method comprises (a) providing a substrate with one or more grooves; (b) rotating and translating an additive friction-stir tool relative to the substrate; (c) feeding a filler material through the additive friction-stir tool; and (d) depositing the filler material into the one or more grooves of the substrate. Translation and rotation of the tool causes heating and plastic deformation of the filler material, which flows into the grooves of the substrate resulting in an interlocking bond between the substrate and filler material. In embodiments, the depositing of the filler material causes deformation of the grooves in the substrate and an interlocking configuration between the grooves of the substrate and the filler material results.

A friction stir welding machine and method that injects filler materials into a weld joint and determines the amount of materials to add by monitoring and compensating for insufficient internal weld pressures in the joint. Two workpieces are placed adjacent one another in an abutting relationship with a joint formed between them. A pin tool is inserted in the joint, rotated, and moved along the joint as the pin is rotating so as to mix and heat materials in the joint. Internal weld pressures in the joint adjacent the pin tool are monitored, and filler materials are injection into the joint when an internal weld pressure below a threshold weld pressure is detected.

A method for coating a workpiece includes a step of applying a coating material to the workpiece and a step of friction welding the coating material to the workpiece.