Friction weld vibration quality monitoring system

Abstract

Friction welding systems and methods including a welding arrangement configured to impart kinetic friction between at least one surface of a first workpiece and at least one surface of a second workpiece to form a weld, a force providing mechanism arranged and disposed for applying a force to one or both of the first workpiece and the second workpiece, and a sensor arranged and disposed to measure a parameter of the welding arrangement, wherein an amount of vibration is determinable from the measured parameter.

1 . A friction welding system comprising:
 a welding arrangement configured to impart kinetic friction between at least one surface of a first workpiece and at least one surface of a second workpiece to form a weld;   a force providing mechanism arranged and disposed for applying a force to one or both of the first workpiece and the second workpiece; and   a sensor arranged and disposed to measure a parameter of the welding arrangement, wherein an amount of vibration is determinable from the measured parameter.   
   
   
       2 . The system of  claim 1 , wherein the welding arrangement comprises:
 a first securing mechanism arranged and disposed to receive and secure the first workpiece; and   a second securing mechanism arranged and disposed to receive and secure the second workpiece, the second securing mechanism being configured to rotate the second workpiece.   
   
   
       3 . The system of  claim 1 , wherein the force providing mechanism is configured to provide the force to one or both of the first workpiece and the second workpiece by a hydraulically driven piston, the piston being configured to urge the first workpiece against the second workpiece. 
   
   
       4 . The system of  claim 1 , further comprising a controller configured to adjust the force applied by the force providing mechanism in response to the measured parameter. 
   
   
       5 . The system of  claim 4 , further comprising a pressure circuit in fluid communication with at least one of the first securing mechanism or the second securing mechanism, wherein the controller is further configured to adjust the force provided by the force providing mechanism by adjusting an adjustable parameter in the pressure circuit. 
   
   
       6 . The system of  claim 5 , wherein the controller is configured to adjust the adjustable parameter by providing fluid pressure pulses. 
   
   
       7 . The system of  claim 5 , wherein the adjustable parameter is fluid pressure in the pressure circuit. 
   
   
       8 . The system of  claim 7 , further comprising a pressure valve arranged and disposed to controllably adjust the fluid pressure in the pressure circuit. 
   
   
       9 . The system of  claim 8 , further comprising a second pressure valve arranged and disposed to controllably adjust the force applied to one or both of the first workpiece and the second workpiece. 
   
   
       10 . The system of  claim 5 , wherein the sensor is configured to measure pressure in the pressure circuit. 
   
   
       11 . The system of  claim 5 , wherein the sensor is configured to measure a fluctuation of the measured parameter in the pressure circuit. 
   
   
       12 . A friction welding system comprising:
 a welding arrangement configured to impart kinetic friction between at least one surface of a first workpiece and at least one surface of a second workpiece to form a weld;   a force providing mechanism arranged and disposed to provide a force to one or both of the first workpiece and the second workpiece;   a sensor arranged and disposed to measure a parameter of the welding arrangement, wherein an amount of vibration is determinable from the measured parameter;   a controller configured to adjust the force provided by the force providing mechanism in response to the measured parameter; and   wherein the sensor is configured to measure the vibration of the welding arrangement, and   wherein the controller is further configured to adjust the force provided by the force providing mechanism by providing pressure pulses or variation in the pressure circuit based upon the measured parameter.   
   
   
       13 . A method of friction welding comprising:
 providing a friction welding system comprising:
 a welding arrangement configured to impart kinetic friction between at least one surface of a first workpiece and at least one surface of a second workpiece to form a weld; 
 a force providing mechanism arranged and disposed for applying a force to one or both of the first workpiece and the second workpiece; and 
 a sensor arranged and disposed measure a parameter of the welding arrangement, wherein an amount of vibration is determinable from the measured parameter; and 
   monitoring the force applied by the force providing mechanism;   determining the amount of vibration in response to the measured parameter;   comparing the amount of vibration to a predetermined amount of vibration; and   generating a signal in response to the amount of vibration.   
   
   
       14 . The method of  claim 13 , wherein the measured parameter is fluid pressure. 
   
   
       15 . The method of  claim 13 , wherein the measured parameter is frequency fluid pressure data from a pressure circuit, the pressure circuit being in fluid communication with at least one of the first securing mechanism or the second securing mechanism. 
   
   
       16 . The method of  claim 15 , further comprising providing a plurality of fluid pressure pulses in the pressure circuit in response to the generated signal. 
   
   
       17 . The method of  claim 13 , further comprising accepting or rejecting the weld formed between the first workpiece and the second workpiece in response to the generated signal. 
   
   
       18 . The method of  claim 13 , further comprising determining whether the vibration can be remedied. 
   
   
       19 . The method of  claim 18 , wherein the determining whether the vibration can be remedied includes performing calculations from data selected from the group consisting of pressure data, a preprogrammed specification, an amount of time the system has tried to remedy the vibration, and combinations thereof