Rolls-royce Corporation

Simon Edward Bray

Andrew Robert Walpole

Gavin J Baxter

Jonathan P Throssell

Gemma A Raven

Michael D Rowlson

John B Brownell

Alistair J E Smith

John P E Forsdike

Tony Jason Sweeting

Amar M Varia

John Forsdike

Robin Wilson

Mark G Horwell

Charlotte Gibson

Stephen M Beech

Peter A Stevens

Andrew Walpole

Gemma Raven

Andrew R Walpole

Michael Rowlson

Jonathan Peter Throssell

John Barry Brownell

A method of friction welding a first component to a second component, the method having the steps of: rotating the first component relative to the second component about a rotation axis; and bringing the first component into contact with the second component; wherein, while the first component and the second component are in contact, a first average force is applied during a first stage of the friction welding process and a second average force is applied during a second stage of the friction welding process; and the second average force is different from the first average force.

Joining method

A method of joining a first component to a second component at respective connection surfaces, comprising, in order, applying a local surface treatment to the connection surface of at least one of the first and second components in order to locally alter the microstructure to a depth of between 60 &#x3bc;m and 10 mm below the connection surface; and joining the first component to the second component using a welding process.

A method of friction welding a first workpiece to a second workpiece, includes the first workpiece with a first faying surface having a first faying length, the second workpiece with a second faying surface having a second faying length, the second faying length greater than the first faying length; positioning the first workpiece adjacent the second workpiece; reciprocating the first workpiece and the second workpiece against one another, the first faying moves relative to the second faying by a sweep length, a temperature at the first and second faying surfaces increases to create a weld interface; each of the first and second workpieces are consumed into the weld interface, adjusting the sweep length the sweep length remains equal to a difference between the second and the first faying lengths; and stopping the reciprocating and allowing the first and second workpieces to cool to weld the first and second workpieces together.

Method of friction welding workpieces by adjusting a sweep length

A rotary friction welding process is provided, including: providing a first axisymmetric workpiece having a first annular weld surface, and a second axisymmetric workpiece having a second annular weld surface; and rotationally welding the workpeices. On the longitudinal section through the aligned workpieces, each of the first and second annular weld surfaces is flanked by radially inner and outer side surfaces, the first weld surface and its side surfaces being shaped to thermally match the second weld surface and its side surfaces across a line of initial contact of the first and second weld surfaces such the heat flows from the weld at all the side surfaces are substantially equal.

Rotary friction welding

The present disclosure provides a rotary friction welding process including: providing an outer axisymmetric workpiece having a front first annular weld surface at a radially inward extent and a rear first annular weld surface at a radially inward extent; providing a front inner axisymmetric workpiece, the front inner workpiece having a front second annular weld surface at a radially outward extent of the front inner workpiece; providing a rear inner axisymmetric workpiece, the rear inner workpiece having a rear second annular weld surface at a radially outward extent of the rear inner workpiece; and rotary welding the workpieces together.

A method for welding together pieces which form a curved or angled end product using a friction welding process. The method includes: providing first and second pieces which together define the end product geometry, each piece including an end product geometry portion and a sacrificial weld portion, the sacrificial weld portion forming a dog-leg relative to the end product geometry portion and terminating in a planar weld interface surface. The pieces are arranged with their planar weld interface surfaces together at a weld surface interface and the sacrificial weld portions in coaxial alignment. Mechanical friction is applied between the planar weld interface surfaces sufficient to plastically deform the sacrificial weld portions. An axial force is applied along the co-axis of the sacrificial weld portions sufficient to upset the sacrificial weld portions and bring together the end product geometry portions. The sacrificial geometry portions are removed to provide the end product.

A friction welding process includes: providing a first workpiece having a first weld surface, and a second workpiece having a second weld surface; aligning the workpieces with the weld surfaces facing each other, moving one workpiece relative to the other workpiece, and engaging the first and second weld surfaces such that the movement raises the temperature at the weld surfaces to create a weld interface; and ceasing the movement and allowing the weld interface to cool to weld the workpieces together at the interface. The first workpiece has a plurality of flash removal channels formed in and/or adjacent to the first weld surface. The channels provide pathways for ejection of material from the weld interface during welding.

Friction welding

A method providing a first tubular workpiece having a first weld surface at an end thereof, and a second tubular workpiece having a second weld surface at an end thereof; aligning the workpieces on a common axis with the weld surfaces facing each other, rotating one workpiece about the axis relative to the other workpiece, and engaging the first and second weld surfaces such that the rotation raises the temperature at the weld surfaces to create a weld interface; and ceasing the rotation and allowing the weld interface to cool to weld the workpieces together at the interface. The first weld surface is an apex region of an annular projection at the end of the first workpiece, on a longitudinal section through the aligned workpieces the annular projection having a profile in which radially inner and outer side surfaces of the annular projection taper towards the apex region.

A method of linear friction welding, the method comprising: a friction phase comprising oscillating a first workpiece () relative to a second workpiece () with a surface of the first workpiece () being forced against a surface of the second workpiece (), such that a plasticised layer is formed at the interface between the first and second workpieces (); wherein the friction phase is divided into a plurality of sub-phases, each sub-phase being configured to form a plasticized layer at the interface between the first and second workpieces (), each plasticized layer comprising a stagnation zone (); wherein the stagnation zone () of one sub-phase is offset from the stagnation zone () of another sub-phase.

Method of linear friction welding

A method is disclosed for controlling a process in which a componentis moved relative to another componentsuch that at least one of the componentsexperiences a reduction in magnitude in at least one dimension. Such processes may include for example friction welding. The method comprises monitoring energy input to the process and adjusting an input parameter for the process based on the monitored energy input. The monitoring of energy input is performed before any reduction in component magnitude has begun to take place.

Process control method

A method of making an aerofoil blink comprising a plurality of aerofoil blades joined to a disc to extend radially outwardly therefrom is provided. The method includes the step of: (a) modelling a linear friction welding process in which a blade member is joined to the disc, the blade member having a stub for joining to the disc, wherein the modelling provides results which are indicative of the welding power at positions along the stub during the welding process; (b) identifying adaptations to the stub using the modelling results to compensate for differences in welding power along the stub during the welding process; (c) providing a blade member having a stub with the identified adaptations; and (d) joining the provided blade member to the disc by the linear friction welding process.

Linear friction welding of an aerofoil blisk

A method of determining the quality of a friction weld between two components, the method comprising joining two components together using a friction welding process, measuring the loss of length of the components as a function of time during the friction welding process, determining the double differential with respect to time of the loss in length of the components as a function of time, determining the quality of the friction weld by calculating the Rvalue of the linear fit to the loss in length of the components as a function of time over a defined time period, determining the end of the defined time period by identifying the start of the final positive peak of the double differential with respect to time of the loss of length of the components as a function of time, calculating Rfrom the least square difference of the linear fit over the defined time period of the loss of length of the components as a function of time and comparing the calculated value of Rwith acceptable values of Rto determine if the quality of the friction weld is acceptable.

Determining the quality of a friction weld using a double differential

A weld enclosure and welding apparatus including a weld enclosure. Also a method of welding. The apparatus has first and second opposed tooling faces adapted to receive and hold respective first and second weld elements. The weld enclosure comprises a housing that allows relative movement between the weld elements and a change in a physical dimension of at least one of the weld elements. The weld enclosure also comprises locating means for locating the housing relative to the welding apparatus and includes heating means.

Friction welding enclosure

A method of friction welding comprises providing a first workpiece having a first weld surface and a second workpiece having a second weld surface. The first workpiece is arranged such that it tapers away from the first weld surface, the first workpiece converges in a direction away from the first weld surface. The first and second workpieces are arranged such that the first weld surface abuts the second weld surface. The first and second workpieces are oscillated relative to each other such that at least one of the weld surfaces of at least one of the workpieces moves relative to the other weld surface of the other workpiece such that the temperature increases at the weld surfaces to create a weld interface. The oscillation is stopped and the first and second weld surfaces are allowed to cool to weld the first and second workpieces together. The tapering of the first workpiece reduces the flow rate of weld flash material during the oscillation of the first and second workpieces relative to each other to reduce the formation of strain-induced porosity at the edges of the weld.

Method of friction welding

A method of friction welding comprising providing a first workpiece () having a first weld surface () and a second workpiece () having a second weld surface (). In a first region () adjacent the first weld surface () the first workpiece () is arranged at an angle (&#x3b1;) of substantially 90&#xb0; to the first weld surface () and in a second region () adjacent to the first region () the first workpiece () tapers away from the first weld surface (). The first workpiece () is arranged such that in the second region () the first workpiece () is arranged at an angle (&#x3b2;) greater than 90&#xb0; and less than 180&#xb0; to the first weld surface (). The first and second workpieces () are arranged such that first weld surface () of the first workpiece () abuts the second weld surface () of the second workpiece (). The first and second workpieces () are moved relative to each other such that the temperature increases at the weld surfaces () to create a weld interface () and then the movement is stopped to cool to weld the first and second workpieces () together.

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Derby, United Kingdom

Simon Edward Bray