Friction stir welding and processing of oxide dispersion strengthened (ODS) alloys

1. A method of welding comprising:

forming a filler material of a first oxide dispersion strengthened metal, the first oxide dispersion strengthened metal having first strengthening particles that compensate for decreases in weld strength of friction stir welded oxide dispersion strengthened metals, wherein the first strengthening particles have a peak concentration diameter ranging from 2 nm to 70 nm;

positioning the filler material between a first metal structure and a second metal structure each being comprised of at least a second oxide dispersion strengthened metal, wherein said filler material is a unitary structure that is positioned along an entirety of an interface to be welded between the first metal structure and the second metal structure,

wherein the concentration of the first strengthening particles in said filler material is 5% to 25% greater than the concentration of second strengthening particles in said first and second metal structures; and

friction welding the filler material, the first metal structure and the second metal structure to provide a weld, wherein said friction welding begins after the unitary structure of the filler material has been positioned along the entirety of the interface to be welded between the first metal structure and the second metal structure.

2. The method of claim 1 , wherein at least one of the filler material, the first metal structure, and the second metal structure are comprised of at least one of a Ni-based material, a Cr-based material, an Al-based material, a Fe-based material, cobalt (Co)-based material, a Ti-based material, or a combination thereof.

3. The method of claim 1 , wherein the first strengthening particles have a peak concentration diameter ranging from about 10 nm to about 30 nm.

4. The method of claim 3 , wherein the at least a second oxide dispersion strengthened metal comprises second strengthening particles having a peak concentration diameter ranging from 2 nm to 1 micron.

5. The method of claim 4 , wherein the at least one of the first strengthening particles and the second strengthening particles are comprised of yttrium (III) oxide (Y 2 O 3 ), aluminum (III) oxide (Al 2 O 3 ), hafnium (IV) oxide (HfO 2 ), lanthanum(III) oxide (La 2 O 3 ), titanium oxide (Ti 2 O 3 ), cerium(IV) oxide (CeO 2 ), and cerium(III) oxide (Ce 2 O 3 ), or a combination thereof.

6. The method of claim 5 , wherein the concentration of the second strengthening particles has a fractional volume that ranges from about 0.3% to about 5%.

7. The method of claim 5 , wherein the concentration of the first strengthening particles is greater than the concentration of second strengthening particles by 10% to 15%.

8. The method of claim 5 , wherein the weld comprises a combination of first strengthening particles and second strengthening particles that ranges from about 15% less to about 15% more than a concentration of second strengthening particles in an unwelded portion of the first and second metal structures.

9. A method of welding comprising:

positioning a filler material comprised of a first oxide dispersion strengthened metal between a first metal structure and a second metal structure, the first metal structure and the second metal structure being comprised of at least a second oxide dispersion strengthened metal having second strengthening particles with a peak concentration diameter ranging from 2 nm to 70 nm, wherein said filler material is a unitary structure that is positioned along an entirety of an interface to be welded between the first metal structure and the second metal structure, and the first oxide dispersion strengthened metal has a concentration of first strengthening particles that is 5% to 25% greater than a concentration of the second strengthening particles in the at least the second oxide dispersion strengthened metal; and

friction welding the filler material, the first metal structure and the second metal structure to provide a weld joining the first metal structure to the second metal structure, wherein said friction welding begins after the unitary structure of the filler material has been positioned along the entirety of the interface to be welded between the first metal structure and the second metal structure.

10. The method of claim 9 , wherein the concentration of the first strengthening particles compensates for the loss of second strengthening particles in the weld that would occur if the filler material was not present.

11. The method of claim 9 , wherein at least one of the filler material, the first metal structure, and the second metal structure are comprised of at least one of a Ni-based material, a Cr-based material, an Al-based material, a Fe-based material, cobalt (Co)-based material, a Ti-based material, or a combination thereof.

12. The method of claim 9 , wherein the first oxide dispersion strengthened metal and the at least the second oxide dispersion strengthened metal includes a strengthening particle having a peak concentration diameter ranging from about 10 nm to about 30 nm.

13. The method of claim, wherein the at least one of the first oxide dispersion metal and the second oxide dispersion strengthened metal comprises a first strengthening particle is an oxide comprised of yttrium (III) oxide (Y 2 O 3 ), aluminum (III) oxide (Al 2 O 3 ), hafnium (IV) oxide (HfO 2 ), lanthanum(III) oxide (La 2 O 3 ), titanium oxide (Ti 2 O 3 ), cerium(IV) oxide (CeO 2 ), and cerium(III) oxide (Ce 2 O 3 ) or a combination thereof.

14. The method of claim 9 , wherein the concentration of the second strengthening particles has a fractional volume that ranges from about 0.3% to about 5%.

15. The method of claim 9 , wherein the concentration of the first strengthening particles is greater than the concentration of second strengthening particles by 10% to 15%.

16. The method of claim 9 , wherein the weld comprises a combination of first strengthening particles and second strengthening particles that ranges from about 15% less to about 15% more than a concentration of second strengthening particles in an unwelded portion of the first and second metal structures.

17. The method of claim 9 , wherein the filler material has a sidewall perpendicular to its base and the filler material extends an entire height of the first metal structure and the second metal structure.

18. The method of claim 9 , wherein the positioning of the filler material between a first metal structure and a second metal structure comprises machining a ledge in the edge of the first metal structure and the second metal structure, and positioning the filler material within the ledge between the first metal structure and the second metal structure.

19. The method of claim 9 , wherein the friction welding of the filler material, the first metal structure and the second metal structure to provide a weld comprises a friction stir weld tool including a pin.

20. The method of claim 9 , wherein the rotation speed of the friction stir weld tool ranges from about 200 rotations per minute to about 2000 rotations per minute.

21. The method of claim 1 , wherein said first and second metal structure are composed of an oxide dispersion strengthened alloy comprising chromium, aluminum, titanium, yttrium, carbon, copper, manganese, cobalt, nickel, phosphorus and iron.

22. The method of claim 1 , wherein said first and second metal structure are composed of an oxide dispersion strengthened alloy comprising nickel, chromium, iron, carbon, aluminum, titanium and yttrium.