EP1510281B1

Method of friction stir welding using an exothermically reactive sealant and friction stir weld joint having an exothermically reacted sealant

Abstract

This record has no abstract on file.

EP1510281B1, drawing sheet 1
Sheet 1 of 4

Term

Term ended

Expired 2 December 2023, 2.8 years ago.

  1. Priority
  2. Filed
  3. Granted
  4. Expired
  5. Today

26 claims: 11 independent, 15 dependent

  1. 1
    A method of forming a weld joint (10), the method comprising:disposing a sealant (40) in an interface (28) defined by first and second faying surfaces (24, 26) of at least one structural member (20, 22);friction welding the at least one structural member (20, 22) by rotating a friction stir welding pin (52) extending from a shoulder (54) and urging the pin (52) through the interface (28) and through the faying surfaces (24, 26) in a direction substantially perpendicular to the interface (28) to thereby friction stir weld the at least one structural member (20, 22) to form a joint (10) between the first and second faying surfaces (24, 26), the joint (10) being at least partially sealed by the sealant (40), wherein said friction stir welding step heats the sealant (40) to an initiation temperature of the sealant (40), thereby initiating an exothermic reaction in the sealant (40) such that the sealant (40) at least partially seals the interface (28) between the faying surfaces (24, 26).
  2. 4
    A method according to one of the preceding Claims wherein said disposing step comprises disposing the sealant (40) as a foil between the faying surfaces (24, 26).
  3. 8
    A method according to one of the preceding Claims, further comprising providing the sealant (40) on a substrate (42), and wherein said disposing step comprises disposing the sealant (40) and the substrate (42) onto at least one of the faying surfaces (24, 26).
  4. 10
    A method according to one of the preceding Claims, wherein said initiating step comprises heating the sealant (40) to an initiation temperature of the sealant (40) and thereby initiating the exothermic reaction of the sealant (40).
  5. 11
    A method according to one of the preceding Claims, further comprising providing the at least one structural member (20, 22), the structural member (20, 22) comprising at least one of the group consisting of aluminum, aluminum alloys, titanium, titanium alloys, and steel.
  6. 12
    A method according to one of the preceding Claims further comprising disposing a braze material (48) in the interface (28), the braze material (48) having a melting temperature lower than a melting temperature of the structural member (20, 22) and the braze material (48) being at least partially bonded to the faying surfaces (24, 26) during an exothermic reaction of the sealant (40).
  7. 14
    A method according to one of the preceding Claims wherein said initiating step comprises initiating an exothermic reaction of the sealant (40), the reaction having a maximum temperature of at least about 1200 °F (649°C).
  8. 15
    A method according to one of the preceding Claims wherein said disposing step comprises disposing the sealant (40) having a thickness of between about 0.0005 and 0.020 inches (0.00127 and 0.0508 cm).
  9. 16
    A method according to one of the preceding Claims wherein said initiating step comprises reacting at least some of the sealant (40) outside the interface (28) to form a fillet seal (46) on at least one edge of the interface (28).
  10. 17
    A method according to one of the preceding Claims further comprising urging said faying surfaces (24, 26) together before said initiating step such that some of the sealant (40) is squeezed from the interface (28) and subsequently exothermically reacted to form a seal on at least one edge of the interface (28).
  11. 18
    A weld joint (10) connecting first and second faying surfaces (24, 26) of at least one structural member (20, 22) defining an interface (28) therebetween, the weld joint (10) being characterised in a friction stir weld joint (12) connecting the faying surfaces (24, 26) at the interface (28) of the faying surfaces (24, 26);and an exothermically reacted sealant (40) disposed in the interface (28) between the faying surfaces (24, 26) at a portion of the interface (28) that is not joined by the friction stir weld joint (12) and at least partially sealing the friction weld joint (12) in the interface (28).