NOSECONES FOR FRICTION STIR ADDITIVE MANUFACTURING SYSTEMS, DEVICES, AND METHODS
A friction stir additive welding device configured to join a first work-piece and second work-piece is provided. In one aspect, the device includes a nosecone having a sidewall extending from a first end to a second end, a channel extending from the first end to the second end along a longitudinal axis of the nosecone, and a screw positioned within the channel. The first end is configured to couple the nosecone to a robotic arm and the second end has a surface configured to be advanced along a weld line between the first and second work-pieces. A central axis of the screw defines an angle that is less than 90 degrees relative to a plane that is perpendicular to surfaces of the first and second work-pieces as the surface of the nosecone advances along the weld line.
1 . A friction stir additive welding device configured to join a first work-piece and a second work-piece comprising:
a nosecone comprising:
a sidewall extending from a first end to a second end, the first end configured to couple the nosecone to a robotic arm and the second end having a surface configured to be advanced along a weld line between the first work-piece and the second work-piece; and
a channel extending from the first end to the second end along a longitudinal axis of the nosecone; and
a screw positioned within the channel, a central axis of the screw defining an angle that is less than 90 degrees relative to a plane that is perpendicular to surfaces of the first work-piece and the second work-piece as the surface of the nosecone advances along the weld line between the first work-piece and the second work-piece.
2 . The device of claim 1 , wherein, when the nosecone is advanced along the weld line between the first work-piece and the second work-piece, the angle is a positive angle.
3 . The device of claim 1 , wherein, when the nosecone is advanced along the weld line between the first work-piece and the second work-piece, the angle is a negative angle.
4 . The device of claim 1 , wherein a longitudinal axis of the nosecone and the plane perpendicular to surfaces of the first work-piece and the second work-piece define a non-90 degree angle.
5 . The device of claim 1 , wherein the surface comprises a first portion and a second portion, wherein the first portion is in a first generally horizontal plane and the second portion is in second generally horizontal plane that is different than the first plane.
6 . The device of claim 1 , further comprising a curved recess in the surface of the second end, the curved recess configured to shape an outer profile of the weld line as the nosecone is advanced along the weld line between the first work-piece and the second work-piece.
7 . The device of claim 6 , wherein the curved recess extends from a perimeter of the channel to an outer edge of the surface of the second end.
8 . The device of claim 6 , wherein the curved recess is formed in a trailing end of the surface of the second end as the nosecone is advanced along the weld line between the first work-piece and the second work-piece.
9 . The device of claim 1 , further comprising a slot comprising a passageway between a slot entrance in an outer sidewall of the nosecone and a slot exit in the channel of the nosecone, the slot configured to receive a portion of a structure positioned between the first work-piece and the second work-piece.
10 . The device of claim 1 , wherein the screw is configured to penetrate a thickness of the first work-piece and a thickness of the second work-piece as the surface advances along the weld line between the first work-piece and the second work-piece.
11 . The device of claim 10 , wherein the screw is configured penetrate an entire thickness of the first work-piece and an entire thickness of the second work-piece as the surface advances along the weld line between the first work-piece and the second work-piece.
12 . A friction stir additive welding device configured to join a first work-piece and a second work-piece comprising:
a nosecone comprising:
a sidewall extending from a first end to a second end, the first end configured to couple the nosecone to a robotic arm and the second end having a surface configured to be advanced along a weld line between the first work-piece and the second work-piece; and
a channel extending from the first end to the second end along a central axis of the nosecone, the central axis of the channel defining an angle that is less than 90 degrees relative to a plane that is perpendicular to surfaces of the first work-piece and the second work-piece as the surface of the nosecone advances along the weld line between the first work-piece and the second work-piece; and
a screw positioned within the channel.
13 . The device of claim 12 , wherein, when the nosecone is advanced along the weld line between the first work-piece and the second work-piece, the angle is a positive angle.
14 . The device of claim 12 , wherein, when the nosecone is advanced along the weld line between the first work-piece and the second work-piece, the angle is a negative angle.
15 . The device of claim 12 , further comprising a recess in the surface of the second end, the recess configured to shape an outer profile of the weld line as the nosecone is advanced along the weld line between the first work-piece and the second work-piece.
16 . A method of joining two parts comprising:
advancing a nosecone of a friction stir additive welding device along a weld line between a first work-piece and a second work-piece;
rotating a screw positioned within a channel of the nosecone while advancing the friction stir additive welding device along the weld line, a central axis of the screw defining an angle less than 90 degrees relative to a plane that is perpendicular to surfaces of the first work-piece and the second work-piece; and
joining the first work-piece and the second work-piece together.
17 . The method of claim 16 , further comprising shaping an outer profile of the weld line with a curved recess in a surface of a trailing end of the nosecone.
18 . The method of claim 16 , wherein the angle is a positive angle.
19 . The method of claim 16 , wherein the angle is a negative angle.
20 . The method of claim 16 , further comprising penetrating the surfaces of the first work-piece and the second work-piece with a tip of the screw.
21 . The method of claim 16 , further comprising penetrating entire thicknesses of the first work-piece and the second work-piece with a tip of the screw.