Systems and methods for reducing stress and distortion during friction welding

Abstract

A method for reducing stress and distortion in a component during a friction welding process includes securing first and second workpieces of the component within an inertia welding machine such that the first and second workpieces are affixed in opposition to each other. The method also includes securing at least one annular support member at least partially around the first workpiece and/or the second workpiece at a location having a reduced cross-section as compared to remaining portions of the first workpiece and/or the second workpiece. Further, the method includes rotating the first workpiece to a predetermined rotational speed. In addition, the method includes engaging the second workpiece with the rotating first workpiece so as to generate frictional heat therebetween, thereby welding the first and second workpieces together. As such, the annular support member(s) supports the location having the reduced cross-section during welding.

1 - 20 . (canceled) 
     
     
         21 . An annular support member assembly for reducing stress and distortion in a component during a friction welding process, the annular support member assembly comprising:
 at least one annular support member sized for securing around a first workpiece and/or a second workpiece at a location having a reduced cross-section, the at least one annular support member comprising a ring-shaped body portion and a plurality of protrusions arranged circumferentially on an exterior surface of the ring-shaped body portion, the plurality of protrusions configured to support the location having the reduced cross-section during a welding procedure, wherein the location having the reduced cross-section comprises a weld.   
     
     
         22 . The annular support member assembly of  claim 21 , wherein the weld comprises an inertia weld. 
     
     
         23 . The annular support member assembly of  claim 21 , wherein each of the plurality of protrusions of the at least one annular support member are spaced apart from an adjacent protrusion via a gap. 
     
     
         24 . The annular support member assembly of  claim 21 , wherein the at least one annular support member further comprises one or more hinges for securing the at least one annular support member to the first workpiece and/or the second workpiece. 
     
     
         25 . The annular support member assembly of  claim 21 , further comprising a plurality of annular support members for securing around the first workpiece and/or the second workpiece at a plurality of locations having a reduced cross-section. 
     
     
         26 . The annular support member assembly of  claim 25 , wherein the plurality of locations having the reduced cross-section comprises a plurality of welds. 
     
     
         27 . The annular support member assembly of  claim 26 , wherein the plurality of welds comprises a plurality of inertia welds. 
     
     
         28 . The annular support member assembly of  claim 25 , wherein the plurality of annular support members respectively have a different shape based on a location where the respective one of the plurality of annular support members is intended to fit on the first workpiece and/or the second workpiece. 
     
     
         29 . The annular support member assembly of  claim 28 , wherein the first workpiece comprises a first rotor stage of a gas turbine engine and wherein the second workpiece comprises a second rotor stage of the gas turbine engine. 
     
     
         30 . The annular support member assembly of  claim 28 , wherein the first workpiece comprises a first portion of a structural casing of a gas turbine engine and wherein the second workpiece comprises a second portion of the structural casing of the gas turbine engine. 
     
     
         31 . The annular support member assembly of  claim 30 , wherein the structural casing of the gas turbine engine comprises a combustor section, a compressor section, or a turbine section. 
     
     
         32 . The annular support member assembly of  claim 21 , wherein the at least one annular support member further comprises one or more jacking features. 
     
     
         33 . The annular support member assembly of  claim 21 , wherein the plurality of protrusions are integral with the ring-shaped body portion. 
     
     
         34 . The annular support member assembly of  claim 21 , wherein the plurality of protrusions are separately attached to the ring-shaped body portion. 
       
         
           
             
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         35 . The annular support member assembly of  claim 21 , wherein the at least one annular support member comprises a plurality of cutouts, wherein the plurality of cutouts are configured to provide increased flexibility to the ring-shaped body portion and/or to allow a decrease in diameter to the ring-shaped body portion during clamping. 
     
     
         36 . The annular support member assembly of  claim 35 , wherein respective ones of the plurality of cutouts are aligned with a gap between respective adjacent ones of the plurality of protrusions. 
     
     
         37 . The annular support member assembly of  claim 35 , wherein respective ones of the plurality of cutouts are arranged on opposite sides of the ring-shaped body portion in an alternating pattern.