Friction stir welding using a superabrasive tool

Abstract

A probe for friction stir welding MMCs, ferrous alloys, non-ferrous alloys, and superalloys, as well as non-ferrous alloys, the probe including a shank, a shoulder, and a pin disposed through the shoulder and into the shank, wherein the pin and the shoulder at least include a coating comprised of a superabrasive material, the pin and shoulder being designed to reduce stress risers, disposing a collar around a portion of the shoulder and the shank to thereby prevent movement of the shoulder relative to the shank, and incorporating thermal management by providing a thermal flow barrier between the shoulder and the shank, and between the collar and the tool.

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         53 . A system for providing a friction stir welding tool that shows improved performance at elevated temperatures, said system comprised of:
 a cylindrical shank;   a shoulder disposed on a working end of the shank;   a bore hole disposed through the shoulder and partially into the shank;   a cylindrical friction stir welding pin disposed in the bore hole, surrounded at least partially by the shoulder on the working end of the shank, the shoulder acting as an inner collar around the friction stir welding pin; and   an outer collar engaged around the inner collar and at least a portion of the shank, to thereby cause the inner collar to compress inward against the friction stir welding pin when the shoulder expands from heating.   
     
     
         54 . The system as defined in  claim 53  wherein the system is further comprised of a thermal barrier disposed between the shoulder and the outer collar. 
     
     
         55 . The system as defined in  claim 53  wherein the system is further comprised of a heating element coupled to the tool to thereby enable heating of the tool to facilitate compression of the friction stir welding pin.