The Boeing Company

The United States of America As Represented by the Administrator of the

Douglas M Todd

Jack Lee Weeks

Peter A Oelgoetz

An apparatus and method for friction stir welding a seam in a hollow container from the inside. The apparatus includes a weld head convertible between a retracted state to an expanded state. The retracted weld head fits through an opening in the container and then expands to enable formation of the weld. The weld head includes a frame and a least one friction stir welding spindle convertible between a retracted position adjacent the frame and an expanded position away from frame. The container may be a pressure vessel tank, with a circular weld being formed between a tubular mid-section and a hemispherical end cap. Desirably, multiple friction stir welding spindles that expand into a common plane are provided, and relative rotation between the weld head and container forms the circular seam. Force balance arms intermediate adjacent friction stir welding spindles expandable to contact the interior of the container may also be provided to help maintain the position of the weld head. Means for rotating the spindles such as a motor may be provided in the frame. An external anvil hoop may be provided surrounding the seam being welded for further backing support for the internal friction stir welding spindles. Cameras adjacent each weld member monitor the weld process, and may provide visual positioning aids.

Friction stir welding of containers from the interior

A process for forming a thin metal coating on a substrate wherein a gas stream heated by an electrical current impinges on a metallic target in a vacuum chamber to form a molten pool of the metal and then vaporize a portion of the pool, with the source of the heated gas stream being on one side of the target and the substrate being on the other side of the target such that most of the metallic vapor from the target is directed at the substrate.

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Hazel Green, AL, United States of America

Douglas M Todd