Friction stir welding (fsw) methods and systems and friction stir welded components made thereby

Abstract

Friction stir welding (FSW) processes, systems and the resulting friction stir welded components are disclosed whereby first and second workpieces are welded to one another using a first workpiece having mutually orthogonal structural components and a junction region therebetween which defines a bearing surface of predetermined geometry. A shoulder of a FSW tool may be brought into bearing contact with the bearing surface so that a pin extending from the shoulder of the FSW tool may be advanced into and through the one structural component of the first workpiece at an angle relative thereto so as to thereby form a friction stir weld region between the first and second workpieces. Some preferred embodiments will provide a bearing surface which defines an arcuately concave geometry, in which case the shoulder of the FSW tool defines an arcuately convex geometry conformably mateable with the bearing surface. According to other preferred embodiments, the bearing surface defines an arcuately convex geometry, in which case the shoulder of the FSW tool defines an arcuately concave geometry conformably mateable with the bearing surface. According to yet other preferred embodiments, the bearing surface and the shoulder of the FSW tool are each planar.