Method of repairing a crack in a component utilizing friction stir welding

1. A method of repairing a crack in a component comprising:

preparing a surrounding surface of the crack for repair;

friction stir welding a first portion of the component on a first side of the crack to a second portion of the component on a second side of the crack to form a fused crack area;

inserting a temporary plug into an existing hole of the component;

friction stir welding said crack

disengaging a friction stir welding tool in a center of a partial exit hole; and

removing said temporary plug from the component.

2. A method as in claim 1 further comprising

inserting a non-consumable fastener in at least one exit hole in the component.

3. A method as in claim 1 comprising:

initiating friction stir welding at a first end of the crack;

friction stir welding to at least a second end of the crack;

drilling a through hole in the component to provide a finished hole; and

inserting a non-consumable fastener in said finished hole.

4. A method as in claim 1 further comprising

drilling a through hole in the component to provide an enlarged or extended finished hole.

5. A method as in claim 1 further comprising:

applying a patch over said fused crack area; and

coupling said patch to the component.

6. A method as in claim 1 wherein applying a patch comprises applying a composite patch.

7. A method as in claim 1 wherein applying a patch comprises applying a metallic patch.

8. A method as in claim 1 wherein coupling said patch comprises bonding said patch to said component via an adhesive material.

9. A method as in claim 1 wherein coupling said patch comprises fastening said patch to said component via a plurality of fasteners.

10. A method as in claim 1 further comprising continuing friction stir welding of the component to an edge of the component using additional tab material.

11. A method as in claim 1 further comprising fusing at least one hole in the component via a retractable pin tool.

12. A method as in claim 1 further comprising friction stir plug welding at least one hole in the component.

13. A method of repairing a crack in a component of an aircraft comprising:

preparing a surrounding surface of the crack for repair;

friction stir welding a first portion of the component on a first side of the crack to a second portion of the component on a second side of the crack to form a fused crack area;

applying a patch over said fused crack area;

coupling said patch to the component;

plug welding at least one hole in the component;

inserting a temporary plug into an existing hole of said at least one hole;

friction stir welding said crack;

disengaging a friction stir welding tool in a center of a partial exit hole; and

removing said temporary plug from the component.

14. A method as in claim 13 wherein applying a patch comprises applying a patch formed of a material selected from at least one of a composite material and a metallic material.

15. A method as in claim 13 wherein friction stir welding comprises utilizing a double-sided tool to apply equal and opposite load on sides of the component.

16. A method of repairing a crack in a component of an aircraft comprising:

preparing a surrounding surface of the crack for repair;

friction stir welding a first portion of the component on a first side of the crack to a second portion of the component on a second side of the crack to form a fused crack area;

applying a patch over said fused crack area;

coupling said patch to the component; and

inserting a fastener in at least one exit hole in the component.

17. A method as in claim 16 wherein applying a patch comprises applying a patch formed of a material selected from at least one of a composite material and a metallic material.

18. A method as in claim 16 wherein friction stir welding comprises utilizing a double-sided tool to apply equal and opposite load on sides of the component.

19. A method as in claim 16 further comprising plug welding at least one hole in the component.

20. A method of repairing a crack in a component of an aircraft comprising:

preparing a surrounding surface of the crack for repair;

inserting a temporary plug into an existing hole;

friction stir welding a first portion of the component on a first side of the crack to a second portion of the component on a second side of the crack to form a fused crack area;

disengaging a friction stir welding tool in a center of a partial exit hole;

removing said temporary plug from the component;

applying a patch over said fused crack area; and

coupling said patch to the component.

21. A method as in claim 20 further comprising

drilling a through hole at an end of said fused crack area to provide a non-plugged finished through hole.