초록 ▼

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 fabric

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.

대표청구항 ▼

1. An additive friction stir fabrication method for repairing a structure, comprising: providing a substrate with a first surface and a second surface, wherein the second surface comprises a cavity;translating a rotating friction-stir tool along the first surface of the substrate;feeding a filler ma

1. An additive friction stir fabrication method for repairing a structure, comprising: providing a substrate with a first surface and a second surface, wherein the second surface comprises a cavity;translating a rotating friction-stir tool along the first surface of the substrate;feeding a filler material through an opening of the rotating friction-stir tool while maintaining the opening positioned above the second surface;depositing the filler material and/or the substrate into the cavity; andproviding a backing anvil in a position relative to the second surface such that the depositing terminates at the backing anvil. 2. The method of claim 1, wherein the second surface is disposed in an interior channel of the substrate, which is a square channel, a rectangular channel, a trapezoidal channel, a circular channel, or a triangular channel. 3. The method of claim 1, wherein the substrate is a pipe or a rail. 4. The method of claim 1, wherein the substrate and/or the filler material are independently chosen from plastics, homo-polymers, co-polymers, polyesters, nylons, polyvinyls such as polyvinyl chloride (PVC), polyethylene terephthalate (PET or PETE), polycarbonate, polylactide, polyacrylics, polystyrenes, polyurethanes, polyolefins such as high density polyethylene (HDPE), low density polyethylene (LDPE) and polypropylene, composites, mixtures, alloys, reinforcement materials, or a metal matrix composite comprising a metal matrix and a ceramic phase, wherein the metal matrix comprises one or more of a metal, a metal alloy, or an intermetallic, and the ceramic phase comprises a ceramic, metals, metallic materials, metal matrix composites (MMCs), ceramics, ceramic materials, steel, Al, Ni, Cu, Mg, Ti, or Fe, or an alloy comprising one or more of these metals, as well as combinations of any of these materials. 5. The method of claim 1, wherein the filler material takes the form of a powder, pellet, rod, solid bar, or powdered-filled cylinder. 6. The method of claim 1, wherein the friction stir tool comprises a throat, and the filler material is fed through the tool by pulling or pushing the filler material through the throat of the friction stir tool. 7. An additive friction stir fabrication method for repairing a structure, comprising: providing a substrate with an interior passageway, wherein the passageway has a wall defined by an outer surface of the substrate and an inner surface of the substrate and a portion of the inner surface of the substrate comprises a void;rotating and translating a friction-stir tool along the outer surface of the substrate; andfeeding the rotating and translating friction-stir tool with a filler material;wherein the translating, rotating, and feeding of the friction-stir tool causes depositing of the substrate or the filler material into the void. 8. The method of claim 7, further comprising providing a backing anvil disposed in the passageway in a manner such that the depositing terminates upon reaching the backing anvil. 9. The method of claim 7, wherein the passageway is a square channel, a rectangular channel, a trapezoidal channel, a circular channel, or a triangular channel. 10. The method of claim 7, wherein the substrate is a pipe or a rail. 11. The method of claim 7, wherein the substrate and/or the filler material are independently chosen from metals, metallic materials, metal matrix composites (MMCs), polymers, polymeric materials, ceramics, ceramic materials, steel, Al, Ni, Cu, Mg, Ti, or Fe, or an alloy comprising one or more of these metals, as well as combinations of any of these materials. 12. The method of claim 7, wherein the filler material takes the form of a powder, pellet, rod, solid bar, or powdered-filled cylinder. 13. The method of claim 7, wherein the filler material and/or the substrate are independently chosen from plastics, homo-polymers, co-polymers, or polymeric materials comprising polyesters, nylons, polyvinyls, such as polyvinyl chloride (PVC), polyacrylics, polyethylene terephthalate (PET or PETE), polylactide, polycarbonates, polystyrenes, polyurethanes, and/or polyolefins, such as high density polyethylene (HDPE), low density polyethylene (LDPE), polypropylene, composites, mixtures, reinforcement materials, or a metal matrix composite comprising a metal matrix and a ceramic phase, wherein the metal matrix comprises one or more of a metal, a metal alloy, or an intermetallic, and the ceramic phase comprises a ceramic, and independently chosen from metals, metallic materials, metal matrix composites (MMCs), ceramics, ceramic materials, steel, Al, Ni, Cu, Mg, Ti, or Fe, or an alloy comprising one or more of these metals, as well as combinations of any of these materials. 14. The method of claim 7, wherein the friction-stir tool comprises a throat and the feeding of the filler material comprises pulling or pushing the filler material through the throat of the friction-stir tool. 15. The method of claim 1, comprising forming a metallurgical, solid state, or mechanical interlocks between the deposited filler material and the substrate. 16. The method of claim 7, comprising forming a metallurgical, solid state, or mechanical interlocks between the deposited filler material and the substrate. 17. The method of claim 1, wherein the depositing provides for repair of the substrate in a manner that provides for enhanced corrosion resistance and/or wear resistance. 18. The method of claim 7, wherein the depositing provides for repair of the substrate in a manner that provides for enhanced corrosion resistance and/or wear resistance.