Linear Friction Welding Component with Shaped Charge

Abstract

A component for use in a linear friction welding system includes a base portion terminating at a predefined boundary plane associated with a weld interface between the component and a further component when the component is welded to the further component. The boundary plane defines a cross sectional area of the component. A shaped charge portion extends from the boundary plane. The shaped charge portion includes a contact initiation portion having a surface area and is configured to provide initial contact between the component and the further component during the welding procedure. The cross sectional area is larger than the surface area.

1 . A component for use in a linear friction welding system, comprising:
 a base portion terminating at a predefined boundary plane associated with a weld interface between the component and a further component when the component is welded to the further component, the boundary plane defining a cross sectional area of the component; and   a shaped charge portion extending from the boundary plane, the shaped charge portion including a contact initiation surface having a surface area, the contact initiation surface configured to provide initial contact between the component and the further component during the welding procedure, wherein the cross sectional area is larger than the surface area.   
     
     
         2 . The component of  claim 1 , wherein:
 the contact initiation surface defines a contact initiation plane; and   the contact initiation plane is parallel to the boundary plane.   
     
     
         3 . The component of  claim 2 , wherein:
 the contact initiation plane is spaced apart from the boundary plane by a shaped charge height; and   the shaped charge height is not greater than 0.15 inches.   
     
     
         4 . The component of  claim 3 , wherein the shaped charge height is not greater than 0.03 inches. 
     
     
         5 . The component of  claim 1 , wherein the shaped charge portion is shaped and sized based upon a predetermined controlled preheating of the component. 
     
     
         6 . The component of  claim 1 , wherein the shaped charge portion of  claim 5 , wherein the contact initiation surface is rectangular. 
     
     
         7 . The component of  claim 6  wherein the shaped charge portion includes a first rectangular surface adjoining the rectangular contact initiation surface and extending to the boundary plane. 
     
     
         8 . The component of  claim 7  wherein the shaped charge portion includes a second rectangular surface adjoining the rectangular contact initiation surface and extending to the boundary plane. 
     
     
         9 . The component of  claim 6  wherein the shaped charge portion forms a truncated pyramid extending from the boundary plane to the rectangular contact initiation surface. 
     
     
         10 . A method of forming a component for use in a linear friction welding system, comprising:
 forming a base portion terminating at a predefined boundary plane associated with a weld interface between the component and a further component when the component is welded to the further component, the boundary plane defining a cross sectional area of the component; and   forming a shaped charge portion extending from the boundary plane, the shaped charge portion including a contact initiation surface having a surface area, the contact initiation surface configured to provide initial contact between the component and the further component during the welding procedure, wherein the cross sectional area is larger than the surface area.   
     
     
         11 . The method of  claim 10 , wherein forming the shaped charge portion comprises:
 forming the contact initiation surface so as to define a contact initiation plane parallel to the boundary plane.   
     
     
         12 . The method of  claim 11 , wherein forming the shaped charge portion comprises:
 spacing the contact initiation plane apart from the boundary plane by a shaped charge height that is not greater than 0.15 inches.   
     
     
         13 . The method of  claim 12 , wherein spacing the contact initiation plane apart from the boundary plane by a shaped charge height comprises:
 spacing the contact initiation plane apart from the boundary plane by a shaped charge height that is not greater than 0.03 inches.   
     
     
         14 . The method of  claim 10 , further comprising:
 identifying a predetermined controlled preheating of the component, wherein forming the shaped charge portion comprises:   identifying a shape and a size of the shaped charge portion based upon the identified predetermined controlled preheating of the component.   
     
     
         15 . The method of  claim 10 , wherein forming the shaped charge portion comprises:
 forming the contact initiation surface as a rectangular contact initiation surface.   
     
     
         16 . The method of  claim 15  wherein forming the shaped charge portion further comprises:
 forming a first rectangular surface adjoining the rectangular contact initiation surface and extending to the boundary plane. 
 
     
     
         17 . The method of  claim 16  wherein forming the shaped charge portion further comprises:
 forming a second rectangular surface adjoining the rectangular contact initiation surface and extending to the boundary plane. 
 
     
     
         18 . The method of  claim 15  wherein forming the shaped charge portion further comprises:
 forming a truncated pyramid extending from the boundary plane to the rectangular contact initiation surface.