Out-of position friction stir welding of high melting temperature alloys

Abstract

A system and method for performing friction stir welding of non-planar materials having high melting temperatures, wherein a process is provided for performing longitudinal and radial welds on objects such as pipes, flanges, tanks, and shrouds, and wherein an active or passive mandrel provides support for the friction stir welding process.

1 . (canceled)  
     
     
         2 . A friction stir welding system that is capable of functionally friction stir welding high melting temperature materials, said system comprising: 
 a friction stir welding tool having a superabrasive material disposed on at least a portion of the friction stir welding tool, wherein the superabrasive material is manufactured under a high temperature and an high pressure process;    a clamping system for holding ends of two cylindrical high melting temperature workpieces together in a position that is suitable for friction stir welding of the two cylindrical high melting temperature workpieces; and    a movable mandrel disposed opposite the friction stir welding tool and inside the two cylindrical high melting temperature workpieces, to thereby create a counter-force to a pressure exerted by the friction stir welding tool on the two cylindrical high melting temperature workpieces, to thereby prevent damage to the two cylindrical high melting temperature workpieces.    
     
     
         3 . The system as defined in  claim 2  wherein the clamping system is further comprised of a first clamp for holding a first pipe, and a second pipe for holding a second pipe.  
     
     
         4 . The system as defined in  claim 3  wherein the clamping system is further comprised of means for rotating the first pipe and the second pipe to enable the friction stir welding tool to remain stationary while the first pipe and the second pipe are rotated underneath the friction stir welding tool.  
     
     
         5 . The system as defined in  claim 3  wherein the clamping system is further comprised of means for rotating the friction stir welding tool while the first pipe and the second pipe are held stationary.  
     
     
         6 . The system as defined in  claim 4  wherein the movable mandrel is further comprised of an anvil for generating at least three points of contact between the movable mandrel and an inside diameter (ID) of one or both of first pipe and the second pipe, wherein one of the at least three points of contact is directly opposite the friction stir welding tool that is pressing against the outside diameter (OD) of one or both of the first pipe and the second pipe.  
     
     
         7 . The system as defined in  claim 6  wherein the anvil for generating the at least three points of contact between the movable mandrel and the ID of the pipe is further comprised of a plurality of pistons, wherein the plurality of pistons are independently controllable to thereby enable at least three to always be in contact with the ID of the pipe.  
     
     
         8 . The system as defined in  claim 7  wherein the anvil is further comprised of at least three hoops, wherein the at least three hoops are pushed by the plurality of pistons, wherein a middle hoop is disposed so as to apply a force opposite the friction stir welding tool, and wherein at least two outer hoops are disposed so as to provide a counter-force to the middle hoop.  
     
     
         9 . The system as defined in  claim 8  wherein the at least three hoops can be moved around the ID of the pipe by the plurality of pistons.  
     
     
         10 . A friction stir welding system that is capable of functionally friction stir welding two pipes together, said system comprising: 
 a clamping system for holding ends of the two pipes together in a position that is suitable for friction stir welding of the two pipes; and    a friction stir welding tool having a superabrasive material disposed on at least a portion of the friction stir welding tool, wherein the superabrasive material is manufactured under a high temperature and a high pressure process.    
     
     
         11 . The system as defined in  claim 10  wherein the clamping system is further comprised of a first clamp for holding a first pipe, and a second pipe for holding a second pipe.  
     
     
         12 . The system as defined in  claim 11  wherein the clamping system is further comprised of means for rotating the two pipes to enable the friction stir welding tool to remain stationary while the two pipes are rotated as the friction stir welding tool makes contact with the two pipes.  
     
     
         13 . The system as defined in  claim 11  wherein the clamping system is further comprised of means for rotating the friction stir welding tool while the two pipes are held stationary.