Additive friction stir methods for joining materials are provided. The methods comprise providing first and second substrates to be joined; providing a forming plate comprising one or more forming cavities; placing the first and second substrates in communication with the forming plate; placing the first and second substrates in communication with each other; rotating and translating an additive friction-stir tool relative to the substrates; feeding a filler material through the additive friction-stir tool; deforming the filler material and the first and second substrates; and extruding one or more of the filler material and the first and second substrates into one or more of the forming cavities of the forming plate. Interaction of the additive friction-stir tool with the substrates generates heat and plastic deformation at the joint to weld the substrates at the joint. The methods include introduction of reinforcing material at the joint through addition of the filler material.

An airfoil may include an airfoil body, a cover, and a stud. The cover may be disposed on at least one of a suction side and a pressure side of the airfoil body and the stud may extend through the cover and into the airfoil body and the stud may be is joined to the airfoil body and the cover by a friction weld.

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 machine includes a robotic arm having a distal end, a tool configured for driving a fastener into a workpiece, and a compensation device mounted between the distal end of the robotic arm and a first end of the tool. The compensation device is configured to move the tool in at least one of a linear and a rotational direction to compensate for deflection of the robotic arm when the fastener is driven into the workpiece.

A method for joining a plurality of workpieces includes providing a rotating drive tool. A fastener is secured to the drive tool. The drive tool is then rotatably driven such that a distal end of the fastener rotates against a surface of the plurality of workpieces. A heated material zone is then generated on the plurality of workpieces as caused by friction from the rotation of the fastener against the surface of the plurality of workpieces. The distal end of the fastener is rotatably and axially driven through the heated material zone. Finally, the drive tool is removed from the fastener, such that when the heated material zone cools, a portion of the heated material zone is fused to the fastener.

A fastener assembly includes a bolt having a shaft and a head. The shaft has proximal and distal shaft ends and a shaft body, with the head at the proximal shaft end. At least a bondable portion of the shaft body is at least partially made of a bondable material. At least one collar has proximal and distal collar ends longitudinally separated by a collar body which includes a longitudinally oriented collar aperture extending through a thickness thereof between proximal and distal collar surfaces. The collar aperture defines an inner collar wall having a bondable portion which is at least partially made of a bondable material. At least the bondable portion of the shaft body is located inside the collar aperture. The bondable material of both of the inner collar wall and the shaft body is activated to bond the shaft and the collar into an integral fastener assembly structure.

A multi-pieces gas turbine engine combustor heat shield is fabricated from sheet metal. The fabrication involves: sheet metal forming a base sheet having opposed hot and cold facing sides, providing cold side details separately from the base sheet, and mounting the cold side details to the cold facing side of the base sheet. The cold side details may be brazed to the base sheet.

The invention relates to a connection element for an interlocking connection to at least one component. The at least one component is held between the connection element and a securing element, and the connection element and the securing element enter into a friction welded connection, having a head with a drive and a shaft, wherein the shaft has at least two cutting structures on its front side. The at least two cutting structures have cutting edges situated in a cutting plane, wherein the cutting plane borders the shaft, and the at least two cutting structures are also spaced apart in the circumferential direction and define a cutting diameter. The shaft also has a cross-section, which has a reduced extension between the cutting structures relative to the cutting diameter, wherein the area of the reduced extension extends in the axial direction at least with the length of the cutting diameter from the cutting structures in the direction of the head.

A mounting tool (1) for mounting a friction-welding boss (9), wherein the mounting tool (1) includes a drive shaft (2) with a first end section (3) adapted to create a detachable force coupling with the friction-welding boss (9) or an adapter and a holder is arranged spring-loaded at the first end section (3) and at least one cutting means (6) is arranged at the holder (5). A milling adapter (10) includes a first end section (11) adapted to create a detachable force coupling with a mounting tool (1), and a second end section (12) including at least one cutting means (13).

An additive friction stir fabrication method and system is described which may be used to fabricate and join a rib to a metallic substrate or to repair a defect in a metallic substrate through extrusion. The method may be carried out with or without the addition of preformed ribs. One such method involves feeding a friction-stir tool with a consumable filler material such that interaction of the friction-stir tool with the substrate generates plastic deformation at an interface between the friction-stir tool and a metallic substrate to bond the plasticized filler and substrate together and extrude this material through a forming cavity to form a rib joined to the metallic substrate. Further described is a system for fabricating a rib joined to a metallic substrate through extrusion.