Solid state joining using additive friction stir processing

1. An additive friction stir method for joining substrates, the method comprising:

providing first and second substrates to be joined;

providing a forming plate comprising one or more forming cavities;

placing one or both of the first and second substrates in communication with the forming plate;

placing the first substrate and the second substrate facing one another;

rotating and translating an additive friction-stir tool relative to a first face of one or both of the first and second substrates, which additive friction-stir tool comprises a throat with an opening for dispensing filler material;

feeding a filler material through the throat of the additive friction-stir tool and dispensing the filler material through the throat opening;

deforming the filler material and the first and second substrates; and

extruding one or more of the filler material and the first and second substrates into one or more of the forming cavities of the forming plate;

wherein during the rotating, translating, and extruding the opening of the throat of the additive friction-stir tool does not penetrate the first face of the first or second substrates.

2. The method of claim 1 , wherein the first and second substrates are a sheet of metal or a metal plate.

3. The method of claim 1 , wherein the first and/or second substrates 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, Cr, Cu, Co, Au, Ag, Mg, Cd, Pb, Pt, Ti, Zn, Fe, Nb, Ta, Mo, W, or an alloy comprising one or more of these metals, as well as combinations of any of these materials.

4. The method of claim 1 , wherein the filler material is provided as a powder, pellet, rod, or powdered-filled cylinder.

5. The method of claim 1 , wherein during rotating and translating the friction-stir tool does not penetrate the first and second substrates.

6. The method of claim 1 , wherein the friction-stir tool has no pin centrally disposed on a shoulder of the tool.

7. The method of claim 1 , further comprising applying a shielding gas through the forming cavity during the translating of the friction-stir tool.

8. The method of claim 1 , wherein joining of the first and second substrates along a joint is caused by frictional heating and compressive loading of the filler material against one or both of the first and second substrates.

9. The method of claim 8 , wherein the filler material is included in the joint.

10. The method of claim 2 , wherein the first and second substrates are in communication with each other along one face of each substrate.

11. The method of claim 10 , wherein the first and second substrates are in communication with each other to provide for a butt joint, a lap joint, a corner joint, a Tee-joint, a flange, a flare, a mechanical weld, an angular weld, or an edge weld.

12. The method of claim 1 , wherein a butt joint is prepared by:

placing a second face of each of the first and second substrates facing each other to provide for a butt joint between the first and second substrates;

placing a third face of each of the first and second substrates in communication with the forming plate;

depositing the filler material from a direction that faces the first face of each of the first and second substrates.

13. The method of claim 12 , wherein the second face of each of the first and second substrates is slanted and when abutted together form an inverted V-shaped groove.

14. The method of claim 1 , wherein the extruding creates a rib in communication with one or both of the substrates.

15. The method of claim 1 , wherein a lap joint is prepared by:

positioning a second face of the first substrate in communication with the forming plate;

positioning a second face of the second substrate in communication with a first face of the first substrate, such that the first substrate is disposed between the forming plate and the second substrate; and

depositing the filler material from a direction that faces the first face of the second substrate.

16. The method of claim 1 , wherein additional filler material is built up on the first face of one or both of the first and second substrates.

17. An additive friction stir method for joining substrates, the method comprising:

providing first and second substrates to be joined;

providing a forming plate comprising one or more forming cavities;

placing one or both of the first and second substrates in communication with the forming plate;

placing the first and second substrates facing each other;

rotating and translating an additive friction-stir tool relative to one or both of the substrates;

feeding a filler material through an opening of the additive friction-stir tool while rotating the filler material, pressing the filler material into one or both of the first and second substrates without the opening of the additive friction-stir tool penetrating the first and second substrates;

while rotating the filler material, pressing the filler material into one or both of the first and second substrates with sufficient pressure to frictionally heat and deform one or both of the first and second substrates with the filler material; and

extruding one or more of the filler material and the first and second substrates into one or more of the forming cavities of the forming plate.

18. The method of claim 17 , wherein the first and/or second substrates 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, Cr, Cu, Co, Au, Ag, Mg, Cd, Pb, Pt, Ti, Zn, Fe, Nb, Ta, Mo, W, or an alloy comprising one or more of these metals, as well as combinations of any of these materials.

19. The method of claim 17 , wherein the filler material is provided as a powder, pellet, rod, or powdered-filled cylinder.

20. The method of claim 17 , wherein the first and second substrates are in communication with each other along one face of each substrate.

21. The method of claim 17 , wherein the first and second substrates are in communication with each other to provide for a butt joint, a lap joint, a corner joint, a Tee-joint, a flange, a flare, a mechanical weld, an angular weld, or an edge weld.

22. The method of claim 17 , wherein the extruding creates a rib in communication with one or both of the substrates.

23. An additive friction stir method for joining substrates, the method comprising:

providing first and second substrates to be joined;

providing a forming plate comprising one or more forming cavities;

placing one or both of the first and second substrates in communication with the forming plate;

placing the first and second substrates facing one another;

providing an additive friction-stir tool comprising a throat disposed on an axis of rotation of the tool, which throat comprises an opening for dispensing a filler material, and the tool comprises no pin through which the filler material is dispensed;

rotating and translating the additive friction-stir tool relative to one or both of the first and second substrates;

feeding the filler material through the throat of the additive friction-stir tool and dispensing the filler material through the throat opening;

deforming the filler material and the first and second substrates; and

extruding one or more of the filler material and the first and second substrates into one or more of the forming cavities of the forming plate.

24. The method of claim 23 , wherein the feeding comprises feeding an amount of the filler material through the tool that is capable of filling one or more of the forming cavities.

25. The method of claim 1 , wherein the first substrate comprises a first material and the second substrate comprises a second material that is different from the first material.

26. The method of claim 17 , wherein the first substrate comprises a first material and the second substrate comprises a second material that is different from the first material.

27. The method of claim 23 , wherein the first substrate comprises a first material and the second substrate comprises a second material that is different from the first material.