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 including a channel extending along a central axis and configured to receive a rotating screw. The device also includes a slot including a first opening in an outer sidewall of the nosecone, a second opening in a wall of the channel of the nosecone, and a passageway through the nosecone between the first opening and the second opening. The slot is configured to receive a portion of a structure positioned between the first work-piece and the second work-piece.
1 . A friction stir additive welding device configured to join a first work-piece and a second work-piece, the device comprising:
a nosecone comprising a channel extending along a central axis of the nosecone to a first end of the nosecone and a curved recess extending from a perimeter of the channel;
a screw configured to rotate within the channel; and
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 at the slot entrance and through the slot exit toward the screw as the nosecone advances across a top surface of the first work-piece and a top surface of the second work-piece.
2 . The device of claim 1 , wherein the structure is a stiffener.
3 . The device of claim 1 , wherein the first end of the nosecone comprises a first surface angled relative to the first work-piece and the second work-piece when the central axis of the nosecone is oriented perpendicular to surfaces of the first work-piece and the second work-piece.
4 . The device of claim 3 , wherein the first end of the nosecone comprises a second surface parallel to the first work-piece and the second work-piece when the central axis of the nosecone is oriented perpendicular to surfaces of the first work-piece and the second work-piece.
5 . The device of claim 4 , wherein a portion of the curved recess is formed in the second surface.
6 . The device of claim 3 , wherein a portion of the curved recess is formed in the first surface.
7 . The device of claim 1 , wherein the slot comprises a width that decreases as the slot extends between the slot entrance in the outer sidewall of the nosecone and the slot exit in the channel of the nosecone.
8 . The device of claim 1 , wherein the slot comprises a first portion and a second portion, the first portion having a narrowing width and the second portion having a constant width.
9 . The device of claim 1 , wherein the slot is configured to reduce motion of the nosecone perpendicular to a direction the nosecone advances along a weld line between the first work-piece and the second work-piece.
10 . The device of claim 1 , wherein the screw comprises a plurality of threads that are configured to break apart and plasticize the portion of the structure as the nosecone is advanced along a weld line between the first work-piece and the second work-piece.
11 . A friction stir additive welding device configured to join a first work-piece and a second work-piece comprising:
a nosecone;
a channel extending along a central axis of the nosecone, the channel configured to receive a rotating screw; and
a slot comprising a first opening in an outer sidewall of the nosecone, a second opening in a wall of the channel of the nosecone, and a passageway through the nosecone between the first opening and the second opening, the slot configured to receive a portion of a structure positioned between the first work-piece and the second work-piece.
12 . The device of claim 11 , wherein a first end of the nosecone comprises a surface angled relative to the first work-piece and the second work-piece when the central axis of the channel is oriented perpendicular to surfaces of the first work-piece and the second work-piece.
13 . The device of claim 11 , wherein a width of the passageway decreases between the first opening and the second opening.
14 . The device of claim 11 , wherein the passageway comprises a first portion and a second portion, the first portion having a narrowing width and the second portion having a constant width.
15 . The device of claim 11 , wherein a first end of the nosecone comprises a curved recess configured to shape an outer profile of a weld line as the nosecone is advanced along the weld line between the first work-piece and the second work-piece.
16 . The device of claim 11 , wherein the slot is configured to reduce motion of the nosecone perpendicular to a direction the nosecone advances as the nosecone is advanced along a weld line between the first work-piece and the second work-piece.
17 . The device of claim 11 , further comprising the rotating screw, the rotating screw comprising a plurality of threads that are configured to break apart and plasticize the portion of the structure as the nosecone is advanced along a weld line between the first work-piece and the second work-piece.
18 . A method of joining two parts and a stiffener 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;
receiving in a slot of the nosecone a portion of a structure positioned between the first work-piece and the 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, the rotation of the screw plasticizing the portion of the structure positioned between the first work-piece and the second work-piece; and
joining the first work-piece, the second work-piece, and the stiffener together.
19 . The method of claim 18 , wherein the rotation of the screw plasticizes portions of the first work-piece and the second work-piece.
20 . The method of claim 18 , further comprising advancing a tip of the screw to a position past first surfaces of the first work-piece and second work-piece and second surfaces of the first work-piece and the second work-piece, the second surfaces opposite the first surfaces.
21 . The method of claim 18 , further comprising, as the nosecone is advanced along the weld line between the first work-piece and the second work-piece, shaping the weld line using a curved recess in a first end of the nosecone.
22 . The method of claim 18 , wherein rotating the screw comprises breaking apart the portion of the stiffener using threads of the screw.
23 . The method of claim 18 , wherein the slot comprises a width that decreases as the slot extends from an outer sidewall of the nosecone to the channel, wherein the method further comprises reducing motion of the nosecone perpendicular to a direction the nosecone advances as the portion of the stiffener passes through the decreased width portion of the slot.
24 . The method of claim 18 , further comprising feeding material through a sidewall of the nosecone as the nosecone is advanced along the weld line between the first work-piece and the second work-piece.