IP Library › Granted Patent US 12,558,739
Granted Patent B2
US 12,558,739 · App. 18/947,554 · Granted Feb 24, 2026

Friction stir additive manufacturing devices and methods for forming in-situ rivets

Inventor: Weidong Song (Woodinville, WA)
Assignee: Blue Origin Manufacturing, LLC
B23K20/128B23K20/1245
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Quick Facts
Patent No.
US 12,558,739
App. No.
18/947,554
Granted
Feb 24, 2026
Kind
B2
Abstract

A method of joining a first work-piece to a second work-piece is provided. Each of the first work-piece and the second work-piece include a top surface, an opposed bottom surface, and a side surface connecting the top surface and the opposed bottom surface. In one aspect, the method includes positioning the side surface of the first work-piece adjacent to the side surface of the second work-piece, and advancing a friction stir additive manufacturing tool across the top surface of the first work-piece and the top surface of the second work-piece along a weld line between the first work-piece and the second work-piece. As the friction stir additive manufacturing tool advances along the weld line, a filler material is deposited along the weld line and into a plurality of through holes formed in either or both of the first work-piece and the second work-piece. Each of the plurality of through holes includes a first opening on the top surface, a second opening on the opposed bottom surface, and a passageway through the work-piece between the first opening and the second opening. The method further includes joining the first work-piece and the second work-piece together.

Claims (24)

1 . A system for joining a first work-piece and a second work-piece, the system comprising:

the first work-piece and the second work-piece, each of the first work-piece and the second work-piece comprising a first surface, an opposed second surface, and a side surface connecting the first surface and the opposed second surface, the side surface of the first work-piece positioned adjacent to the side surface of the second work-piece, either or both of the first work-piece and the second work-piece comprising a plurality of through holes, each of the plurality of through holes comprising a first opening on the first surface, a second opening on the opposed second surface, and a passageway through the work-piece between the first opening and the second opening; and

a friction stir additive manufacturing tool configured to advance across the first surface of the first work-piece and the first surface of the second work-piece along a weld line between the first work-piece and the second work-piece, the friction stir additive manufacturing tool further configured to deposit a filler material along the weld line and into the plurality of through holes of either or both of the first work-piece and the second work-piece as the friction stir additive manufacturing tool advances along the weld line between the first work-piece and the second work-piece, the filler material configured to harden within one or more of the plurality of through holes.

2 . The system of claim 1 , wherein the side surface of the first work-piece is positioned in direct contact with the side surface of the second work-piece.

3 . The system of claim 1 , wherein the side surface of the first work-piece is positioned in indirect contact with the side surface of the second work-piece.

4 . The system of claim 1 , wherein the side surface of the first work-piece is spaced a distance from the side surface of the second work-piece.

5 . The system of claim 1 , further comprising a stiffener positioned between the side surface of the first work-piece and the side surface of the second work-piece, wherein the friction stir additive manufacturing tool is configured to deposit the filler material between the first work-piece, the stiffener, and the second work-piece.

6 . The system of claim 1 , wherein the first work-piece and the second work-piece comprise a plurality of through holes.

7 . The system of claim 1 , wherein each of the plurality of through holes extend along an axis generally parallel to and offset a distance from the weld line.

8 . The system of claim 1 , wherein the first work-piece comprises a first material and the second work-piece comprises a second material different than the first material.

9 . The system of claim 8 , wherein the filler material is the same as one of the first material and the second material.

10 . A system for joining a first work-piece and a second work-piece, the system comprising:

a mold defining a cavity;

the first work-piece and the second work-piece positioned above the mold, each of the first work-piece and the second work-piece comprising a first surface, an opposed second surface, and a side surface connecting the first surface and the opposed second surface, the side surface of the first work-piece positioned adjacent to the side surface of the second work-piece, either or both of the first work-piece and the second work-piece comprising a plurality of through holes, each of the plurality of through holes comprising a first opening on the first surface, a second opening on the opposed second surface, and a passageway through the work-piece between the first opening and the second opening; and

a friction stir additive manufacturing tool configured to advance across the first surface of the first work-piece and the first surface of the second work-piece along a weld line between the first work-piece and the second work-piece, the friction stir additive manufacturing tool further configured to deposit a filler material along the weld line and into the plurality of through holes of either or both of the first work-piece and the second work-piece and the cavity of the mold, the filler material configured to harden within one or more of the plurality of through holes.

11 . The system of claim 10 , wherein the first work-piece and the second work-piece comprise a plurality of through holes.

12 . The system of claim 10 , wherein each of the plurality of through holes extend along an axis generally parallel to and offset a distance from the weld line.

13 . The system of claim 10 , wherein the first work-piece comprises a first material and the second work-piece comprises a second material different than the first material.

14 . The system of claim 13 , wherein the filler material is the same as one of the first material and the second material.

15 . The system of claim 10 , wherein the mold comprises a first portion and a second portion, the first portion and the second portion defining the cavity.

16 . The system of claim 10 , wherein the mold comprises a single portion, the single portion defining the cavity.

17 . The system of claim 10 , wherein the cavity is shaped and sized to form a stiffener.

18 . The system of claim 10 , wherein the cavity is shaped and sized to form a stiffener having a bulb or rounded surface.

19 . The system of claim 10 , wherein the side surface of the first work-piece and the side surface of the second work-piece are spaced a distance substantially equal to a width of the cavity.

Assignments (2)
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Mar 20, 2025
From: BLUE ORIGIN, LLC
To: BLUE ORIGIN MANUFACTURING, LLC
Reel/Frame 070585/0358 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Feb 13, 2025
From: SONG, WEIDONG
To: BLUE ORIGIN, LLC
Reel/Frame 070211/0059 →
Continuity (2)
Continuation 18192970 · Mar 30, 2023
Related Publication 20250135574A1 · May 1, 2025
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