Aeroprobe Corporation

Virginia Tech Intellectual Properties, Inc.

Meld Manufacturing Corporation

Schultz-creehan Holdings, Inc.

Jeffrey Patrick Schultz

Kevin D Creehan

Kumar Kandasamy

Stephen Lynn Kampe

Ben David Poquette

Jennifer Franklin

Alexander O Aning

Ted Ankomahene Asare

Adam Goff

A method for joining materials using additive friction stir techniques is provided. The method joins a material to a substrate, especially where the material to be joined and the substrate are dissimilar metals. One such method comprises (a) providing a substrate with one or more grooves; (b) rotating and translating an additive friction-stir tool relative to the substrate; (c) feeding a filler material through the additive friction-stir tool; and (d) depositing the filler material into the one or more grooves of the substrate. Translation and rotation of the tool causes heating and plastic deformation of the filler material, which flows into the grooves of the substrate resulting in an interlocking bond between the substrate and filler material. In embodiments, the depositing of the filler material causes deformation of the grooves in the substrate and an interlocking configuration between the grooves of the substrate and the filler material results.

In-situ interlocking of metals using additive friction stir processing

An additive friction stir fabrication method and system is described which may be used to fabricate and join a rib to a metallic substrate or to repair a defect in a metallic substrate through extrusion. The method may be carried out with or without the addition of preformed ribs. One such method involves feeding a friction-stir tool with a consumable filler material such that interaction of the friction-stir tool with the substrate generates plastic deformation at an interface between the friction-stir tool and a metallic substrate to bond the plasticized filler and substrate together and extrude this material through a forming cavity to form a rib joined to the metallic substrate. Further described is a system for fabricating a rib joined to a metallic substrate through extrusion.

Additive friction-stir fabrication system for forming substrates with ribs

The present invention relates to tooling and methods for disposing, coating, building up, repairing, or otherwise modifying the surface of a metal substrate using frictional heating and compressive loading of a consumable metal material against the substrate. Embodiments of the invention include friction-based fabrication tooling comprising a non-consumable member with a throat and a consumable member disposed in the throat, wherein the throat is operably configured such that during rotation of the non-consumable member at a selected speed, the throat exerts normal forces on and rotates the consumable member at the selected speed; and comprising means for dispensing the consumable member through the throat and onto a substrate using frictional heating and compressive loading. Embodiments of the invention also include fabrication methods using the tools described herein.

Metal matrix composite creation

Additive friction stir methods for repairing substrates, coating substrates, fabricating/adding/attaching ribs, joining substrates, stiffening and enhancing structures, surface modification, enhancing surface properties, welding, coating, and extrusion are described. An additive friction stir fabrication method and system is described which may be used to fabricate and join a rib to a substrate or to repair a defect in a substrate through extrusion. The method may be carried out with or without the addition of preformed ribs. One such method involves feeding a friction-stir tool with a consumable filler material such that interaction of the friction-stir tool with the substrate generates plastic deformation at an interface between the friction-stir tool and a substrate to bond the plasticized filler and substrate together and extrude this material through a forming cavity to form a rib joined to the substrate. Further described is a system for fabricating a rib joined to a substrate through extrusion.

Additive friction stir methods of repairing substrates

Fabrication tools for exerting normal forces on feedstock

Fabrication of monolithic stiffening ribs on metallic sheets

A low-temperature friction-based coating method termed friction stir fabrication (FSF) is disclosed, in which material is deposited onto a substrate and subsequently stirred into the substrate using friction stir processing to homogenize and refine the microstructure. This solid-state process is capable of depositing coatings, including nanocrystalline aluminum and/or metal matrix composites and the like, onto substrates such as aluminum at relatively low temperatures. A method of making rod stock for use in the FSF process is also disclosed.

Friction stir fabrication

The present invention relates to tools and methods for disposing, coating, repairing, or otherwise modifying the surface of a metal substrate using frictional heating and compressive/shear loading of a consumable metal against the substrate. Embodiments of the invention include friction-based fabrication tooling comprising a non-consumable member with a throat and a consumable member disposed in the throat, wherein consumable filler material is capable of being introduced to the throat in a continuous manner during deposition using frictional heating and compressive/shear loading of the filler material onto the substrate. Preferred embodiments according to the invention include such tools operably configured for applying a force or displacement to the filler material during deposition. Especially preferred embodiments can include using various powder-type consumable materials or combinations during the deposition process to obtain a continuous compositional gradient in the filler material yielding a functionally graded coating on the substrate.

System for continuous feeding of filler material for friction stir welding, processing and fabrication

Friction fabrication tools

The present invention relates to tools and methods for welding, coating, repairing, or otherwise modifying the surface of a metal substrate. More specifically, embodiments of the present invention provide self-reacting friction stir welding tools which have an internal channel that allows filler materials to be added to the weld joint or otherwise friction stir processed area. Embodiments also provide friction stir tooling having upper and lower shoulders disposed at a fixed distance from one another and connected by a fixed split-pin. The tooling can be configured for automatically dispensing varying amounts of filler material into the tooling in response to variations in thickness of a substrate being processed.

Self-reacting friction stir welding tool with the ability to add filler material

Composite materials comprising ferroelastic ceramic particulates dispersed in a metal matrix are capable of vibration damping. When the ferroelastic ceramic particulates are subjected to stress, such as the cyclic stress experienced during vibration of the material, internal stresses in the ceramic cause the material to deform via twinning, domain rotation or domain motion thereby dissipating the vibrational energy. The ferroelastic ceramic particulates may also act as reinforcements to improve the mechanical properties of the composites. The composite materials may be used in various structural components in vehicles, aircraft, spacecraft, buildings and tools.

Ferroelastic ceramic-reinforced metal matrix composites

Composite materials comprising piezoelectric ceramic particulates dispersed in a metal matrix are capable of vibration damping. When the piezoelectric ceramic particulates are subjected to strain, such as the strain experienced during vibration of the material, they generate an electrical voltage that is converted into Joule heat in the surrounding metal matrix, thereby dissipating the vibrational energy. The piezoelectric ceramic particulates may also act as reinforcements to improve the mechanical properties of the composites. The composite materials may be used in various structural components in vehicles, aircraft, spacecraft, buildings and tools.

Growing community of inventors

Blacksburg, VA, United States of America

Jeffrey Patrick Schultz