A method of manufacturing a liquid-cooled jacket, includes a preparation step which includes placing a sealing body on a stepped portion to allow a step side surface and a sealing-body side surface of the sealing body to butt each other, and a primary joining step which includes allowing a primary joining rotary tool to move once around the sealing body, while moving the rotary tool along a butted portion formed in the preparation step, to carry out friction stir welding. The primary joining step includes employing the primary joining rotary tool provided with a stirring pin having a length dimension greater than a thickness dimension of the sealing body, and carrying out friction stirring with only the stirring pin being brought into contact with a jacket body and the sealing body.

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.

A method of using friction stir processing to repair a defect in a pre-existing weld of a pipeline of steel or other ferrous alloy. The method comprises attaching run-on and run-off tabs to the pipeline on respective sides of the defect and then advancing a friction stir processing tool into the nm-on tab. The tool is moved from the nm-on tab to the run-off tab along a weld-processing path that incorporates the defect. Once the defect is repaired, the tool is removed from the run-off tab. The run-on and run-off tabs may then be removed from the pipeline. The nm-on and nm-off tabs are generally wedge-shaped, each comprising an inner seating face and an outer running face that converges with the inner seating face. When attached to the pipeline, the tabs toward each other about the circumference of the pipeline.

The invention relates to a joint and welding configuration used during repair of metal and metal alloy plates specifically for providing a means of joining metal plates and filling voids in metal plates where access from one side is restricted. A joint arrangement suitable for repairing a void in at least one element, wherein said at least one element has a first surface and a second surface, wherein the thickness of the at least one element is at least 10 mm, further comprising two or more insert elements, each of said two or more insert elements each being friction stir welded at their abutted surfaces to said at least one element, characterized wherein said at least one element comprises at least one recess portion, wherein a Friction Stir Weld is caused from the direction of said first surface.

A friction stir welding method of welding first and second members to each other by rotating and pressing a friction stir tool into butt surfaces of the first and second members and moving the friction stir tool while rotating the friction stir tool, includes: a butt process of abutting the first and second members on each other, and abutting a side surface of a third member on side surfaces of the first and second members; an offset process of making a rotation center of the friction stir tool coincide with a position offset from the butt surfaces, and moving the friction stir tool to reach an inside of the third member; and a welding process of making the rotation center coincide with the butt surfaces, and moving the friction stir tool to reach the inside of the third member.

A method of manufacturing a liquid-cooled jacket, includes a preparation step which includes placing a sealing body on a stepped portion to allow a step side surface and a sealing-body side surface of the sealing body to butt each other, and a primary joining step which includes allowing a primary joining rotary tool to move once around the sealing body, while moving the rotary tool along a butted portion formed in the preparation step, to carry out friction stir welding. The primary joining step includes employing the primary joining rotary tool provided with a stirring pin having a length dimension greater than a thickness dimension of the sealing body, and carrying out friction stirring with only the stirring pin being brought into contact with a jacket body and the sealing body.

A method of manufacturing a liquid-cooled jacket, includes a preparation step which includes placing a sealing body on a stepped portion to allow a step side surface and a sealing-body side surface of the sealing body to butt each other, and a primary joining step which includes allowing a primary joining rotary tool to move once around the sealing body, while moving the rotary tool along a butted portion formed in the preparation step, to carry out friction stir welding. The primary joining step includes employing the primary joining rotary tool provided with a stirring pin having a length dimension greater than a thickness dimension of the sealing body, and carrying out friction stirring with only the stirring pin being brought into contact with a jacket body and the sealing body.

A friction stir welding method which permits advantageous production of a product which has a sound welded area without joint defects, by joining together two members formed of the same material or respective different materials selected from a cast aluminum alloy and 2000 series, 4000 series, 5000 series and 7000 series aluminum alloys which are considered difficult to be joined together by the friction stir welding method. An initiation tab member formed of a 1000 series, 3000 series, 6000 series or 8000 series aluminum alloy is disposed in abutting contact with end faces of joining portions of first and second members (in an abutting part), on the side of initiation of the welding operation, and the friction stir welding operation is performed by moving a probe of a rotary tool through the initiation tab member into the joining portions of the two members.

The present invention includes: a primary joining process in which a coarse portion having a predetermined width is formed in the vicinity of a step side face within a plasticized region while the rotary tool is being moved one round along a first butted portion to perform friction stirring in a state that a tip of a stirring pin of a rotary tool being rotated is inserted to the same depth as or slightly deeper than a step bottom face and a bottom face of a shoulder portion is in contact with a front face of a sealing body and the stirring pin is slightly in contact with at least an upper portion of a jacket body; and an inspection process in which a passed position of the stirring pin is specified by performing, after the primary joining process, a flaw detection to detect the coarse portion.