Solid state processing of industrial blades, edges and cutting elements

1 . A method for creating an industrial blade, said method comprising the steps of:

1) providing a high melting temperature workpiece that is to be formed into an industrial blade;

2) providing a friction stir processing tool that includes a higher melting temperature material than the workpiece on a portion thereof; and

3) friction stir processing the workpiece using the tool to thereby modify characteristics thereof; and

4) forming the industrial blade from the workpiece.

2 . The method as defined in claim 1 wherein the method further comprises the step of causing a substantially solid state transformation without passing though a liquid state of the workpiece.

3 . The method as defined in claim 1 wherein the step of providing the high melting temperature workpiece includes selecting the high melting temperature workpiece from the group of high melting temperature materials including ferrous alloys, non-ferrous materials, superalloys, titanium, cobalt alloys typically used for hard-facing, and air hardened or high speed steels.

4 . The method as defined in claim 1 wherein the method further comprises the step of synthesizing a new material from solid state processing of the workpiece, wherein the new material has characteristics that are advantageous to an industrial blade.

5 . The method as defined in claim 1 wherein the method further comprises the steps of:

1) providing an additive material; and

2) friction stir mixing an additive material into the workpiece to thereby modify at least one characteristic of the workpiece.

6 . The method as defined in claim 1 wherein the method further comprises the step of modifying a microstructure of the workpiece.

7 . The method as defined in claim 6 wherein the method further comprises the step of modifying a macrostructure of the workpiece.

8 . The method as defined in claim 7 wherein the step of modifying the microstructure includes increasing toughness of the workpiece.

9 . The method as defined in claim 7 wherein the step of modifying the microstructure includes increasing or decreasing hardness of the workpiece.

10 . The method as defined in claim 7 wherein the step of modifying the microstructure includes increasing or decreasing strength of the workpiece.

11 . The method as defined in claim 7 wherein the step of modifying the microstructure includes friction stir processing the workpiece to thereby obtain superior edge retention on the industrial blade that is formed therefrom.

12 . The method as defined in claim 7 wherein the step of modifying the microstructure includes friction stir processing the workpiece to thereby obtain superior resistance to chipping on the industrial blade that is formed therefrom.

13 . The method as defined in claim 1 wherein the step of providing the friction stir processing tool further includes the step of providing the friction stir processing tool having a shank, a shoulder and a pin.

14 . The method as defined in claim 13 wherein the step of providing the friction stir processing tool having a shank, a shoulder and a pin further comprises the step of including a superabrasive material.

15 . The method as defined in claim 15 wherein the method further comprises the step of friction stir processing without plunging the pin into the workpiece.

16 . The method as defined in claim 1 wherein the step of providing the friction stir processing tool further includes the step of providing the friction stir processing tool having a shank and a shoulder.

17 . A hand-held knife with a blade having improved edge retention and resistance to chipping, said industrial blade comprised of a high melting temperature workpiece, wherein the high melting temperature workpiece is created through friction stir processing.

18 . A system for manufacturing a hand-held knife blade through friction stir processing, said system comprised of:

a high melting temperature workpiece; and

a friction stir processing tool that includes a higher melting temperature material than the workpiece on a portion thereof, wherein the tool is used to perform friction stir processing to thereby cause solid state transformation of the workpiece, wherein characteristics of the workpiece are modified.

19 . The system as defined in claim 18 wherein the tool is further comprised of a shank, a shoulder and a pin.

20 . The system as defined in claim 18 wherein the tool is further comprised of a shank and a shoulder.