Welded joints with polymer sealant
View Patent ↗An assembly, such as an aircraft component, is formed with a weld joint by, for example, using friction stir welding, FSW, to form a lap joint between a stiffer and the interior surface of the skin of the component. A sealant layer, such as a monomer sealant/adhesive is applied to the surfaces to be joined, and is cured in place by the elevated temperatures of the welding process to form an elastomeric fay surface sealing, such as a fluoroelastomeric coating, to protect the component from corrosion at the welds. Additional heat for curing may be applied by laser or induction heating or the like.
1. A method of welding comprising:
positioning a monomer between surfaces to be welded together; and
friction stir welding at least portions of the surfaces through the monomer to form a welded joint and to form a corrosion barrier sealant resisting the intrusion of moisture by capillary action adjacent the welded joint between the surfaces by at least partially polymerizing the monomer.
2. The invention of claim 1 further comprising:
selecting a monomer through which a welded joint can be formed by friction stir welding without substantial degradation of the corrosion barrier sealant.
3. A method of welding comprising:
selecting an elastomeric monomer through which a welded joint can be formed by friction stir welding without substantial degradation of the welded joint;
positioning the elastomeric monomer which is at least partially cured without substantial damage by temperatures produced during friction stir welding between surfaces to be welded together; and
friction stir welding at least portions of the surfaces through the monomer to form a welded joint and to form a corrosion barrier sealant adjacent the welded joint between the surfaces by at least partially curing the monomer.
4. A method of welding comprising:
positioning a monomer, which is at least partially cured without substantial damage by temperatures produced during friction stir welding between surfaces to be welded together;
partially curing the monomer before welding; and
friction stir welding at least portions of the surfaces through the monomer to form a welded joint and to form a sealant adjacent the welded joint between the surfaces by at least partially curing the monomer.
5. The invention of claim 4 wherein welding further comprises:
completing the curing of the monomer.
6. The invention of claims 1 or 2 wherein positioning the monomer further comprises:
applying an elastomeric monomer.
7. A method of welding comprising:
applying an adhesive monomer, which is at least partially cured without substantial damage by temperatures produced during friction stir welding, between surfaces to be welded together;
partially curing the monomer before welding; and
friction stir welding at least portions of the surfaces through the monomer to form a welded joint and to form a sealant adjacent the welded joint between the surfaces by at least partially curing the monomer.
8. A method of welding comprising:
positioning a monomer which is at least partially cured without substantial damage by temperatures produced during friction stir welding between surfaces to be welded together; and
friction stir welding at least portions of the surfaces through the monomer to form a welded joint and to form a corrosion barrier sealant adjacent the welded joint between the surfaces by at least partially curing the monomer by at least partially polymerizing the monomer.
9. The invention of claims 1 or 2 further comprising:
applying additional heat to polymerize the monomer.
10. A method of welding comprising:
positioning a monomer, which is at least partially cured without substantial damage by temperatures produced during friction stir welding, between surfaces to be welded together;
applying heat in the form of laser energy to cure the monomer; and
friction stir welding at least portions of the surfaces through the monomer to form a welded joint and to form a sealant adjacent the welded joint between the surfaces by at least partially curing the monomer.
11. The invention of claims 1 or 2 wherein welding further comprises:
forming a lap joint.
12. A method of welding comprising:
applying an elastomeric monomer, which is at least partially cured without substantial damage by temperatures produced during friction stir welding, between surfaces to be welded together; and
friction stir welding at least portions of the surfaces through the monomer to form a welded joint and to form a corrosion barrier sealant adjacent the welded joint between the surfaces by at least partially curing the monomer.
13. The invention of claims 12 or 3 wherein positioning a monomer further comprises:
applying a fluoroelastomeric monomer.
14. A method of welding comprising:
selecting a monomer through which a welded joint can be formed by friction stir welding without substantial degradation of the welded joint;
positioning the monomer, which is at least partially cured without substantial damage by temperatures produced during friction stir welding, between surfaces to be welded together;
partially curing the monomer before welding; and
friction stir welding at least portions of the surfaces through the monomer to form a welded joint and to form a sealant adjacent the welded joint between the surfaces by at least partially curing the monomer.
15. The invention of claim 14 wherein welding further comprises:
completing the curing of the monomer.
16. A method of welding comprising:
selecting an adhesive monomer through which a welded joint can be formed by friction stir welding without substantial degradation of the welded joint;
applying the monomer, which is at least partially cured without substantial damage by temperatures produced during friction stir welding, between surfaces to be welded together;
partially curing the monomer before welding; and
friction stir welding at least portions of the surfaces through the monomer to form a welded joint and to form a sealant adjacent the welded joint between the surfaces by at least partially curing the monomer.
17. A method of welding comprising:
selecting an adhesive monomer through which a welded joint can be formed by friction stir welding without substantial degradation of the welded joint;
positioning the monomer, which is at least partially cured without substantial damage by temperatures produced during friction stir welding, between surfaces to be welded together;
applying heat in the form of laser energy to core the monomer; and
friction stir welding at least portions of the surfaces through the monomer to form a welded joint and to form a sealant adjacent the welded joint between the surfaces by at least partially curing the monomer.
18. A method of welding comprising:
selecting a monomer which forms a corrosion barrier when cured;
positioning the monomer between surfaces to be welded together; and
polymerizing the monomer by friction stir welding at least portions of the surfaces through the monomer to form a welded joint surrounded by a moisture resistant corrosion barrier sealant between the surfaces.
19. A method of welding comprising:
selecting a monomer which forms a corrosion barrier when cured;
positioning the monomer between surfaces to be welded together;
at least partially curing the monomer before welding; and
curing the monomer by friction stir welding at least portions of the surfaces through the monomer to form a welded joint surrounded by a corrosion barrier sealant between the surfaces.
20. The invention of claim 19 wherein the monomer is an adhesive monomer.
21. A method of welding comprising:
selecting a monomer through winch a welded joint can be formed by friction stir welding without substantial degradation of the welded joint;
positioning the monomer which is at least partially cured without substantial damage by temperatures produced during friction stir welding between surfaces to be welded together; and
friction stir welding at least portions of the surfaces through the monomer to form a welded joint and to form a corrosion barrier sealant adjacent the welded joint between the surfaces by at least partially polymerizing the monomer.
22. The invention of claims 4 , 7 , 10 , 12 , 14 , 16 , 17 , 19 or 3 wherein curing the monomer further comprises:
polymerizing the monomer.
23. The invention of claim 22 wherein the monomer is an elastomeric monomer.
24. The invention of claim 22 wherein the monomer is a fluroelastomeric monomer.