Swage and flare joints

Abstract

In one example, an elongate member includes an unswaged portion of metal, and a swaged portion of metal and attached to the unswaged portion. The swaged portion includes four walls that cooperate to define a perimeter of the swaged portion, each of the walls being substantially straight and two of the walls terminating together at a common point such that an angle between the two walls of about 90 degrees is defined. A respective local deformation is defined in each of the four walls, and an attribute of one of the local deformations varies along a portion of a length of the swaged portion.

What is claimed is: 
     
         1 . An elongate member, comprising:
 an unswaged portion comprising metal; and   a swaged portion comprising metal and attached to the unswaged portion, the swaged portion comprising:
 four walls that cooperate to define a perimeter of the swaged portion, each of the walls being substantially straight and two of the walls terminating together at a common point such that an angle between the two walls of about 90 degrees is defined; and 
 a respective local deformation defined in each of the four walls, wherein an attribute of one of the local deformations varies along a portion of a length of the swaged portion. 
   
     
     
         2 . The elongate member as recited in  claim 1 , wherein the swaged portion is configured to be received in a corresponding flared portion of another member such othat substantial portions of the two walls proximate their common point of termination are in contact with corresponding walls of the flared portion. 
     
     
         3 . The elongate member as recited in  claim 1 , wherein the swaged portion is substantially hollow, or substantially solid. 
     
     
         4 . The elongate member as recited in  claim 1 , wherein except for the presence of the local deformation, each of the walls that includes a local deformation is substantially undeformed. 
     
     
         5 . The elongate member as recited in  claim 1 , wherein a portion of one of the local deformations has a curved cross-sectional shape. 
     
     
         6 . The elongate member as recited in  claim 1 , wherein the swaged portion has a cross-sectional shape that is substantially square, or substantially rectangular. 
     
     
         7 . The elongate member as recited in  claim 1 , wherein the local deformations all have substantially the same size and configuration. 
     
     
         8 . An apparatus, comprising:
 a first member, comprising:
 an unswaged portion comprising metal; and 
 a swaged portion comprising metal and attached to the unswaged portion, the swaged portion comprising:
 four walls that cooperate to define a perimeter of the swaged portion, each of the walls being substantially straight and two of the walls terminating together at a common point such that an angle between the two walls of about 90 degrees is defined; and 
 a respective local deformation defined in each of the four walls; and 
 
   a second member configured to receive the swaged portion of the first member, wherein when the swaged portion is fully received in the second member, respective portions of the two walls extending between the common point of termination and nearest local deformation are in contact with corresponding walls of the second member.   
     
     
         9 . The apparatus as recited in  claim 8 , wherein one or more of the local deformations includes a curved portion. 
     
     
         10 . The apparatus as recited in  claim 8 , wherein the second member includes a flared portion configured to receive the swaged portion of the first member such that the swaged portion contacts the flared portion when the swaged portion is received in the flared portion. 
     
     
         11 . The apparatus as recited in  claim 8 , wherein the local deformations all have substantially the same size and configuration. 
     
     
         12 . The apparatus as recited in  claim 8 , wherein the swaged portion has a cross-sectional shape that is substantially square, or substantially rectangular. 
     
     
         13 . The apparatus as recited in  claim 8 , wherein each wall has two straight portions, one straight portion adjoining either side of the local deformation in that wall, and each straight portion adjoining another straight portion of another of the walls. 
     
     
         14 . The apparatus as recited in  claim 8 , wherein one of the local deformations protrudes inwardly from an exterior surface of the swaged portion. 
     
     
         15 . A structure, comprising:
 a swaged portion substantially made of metal, and comprising:
 four walls, the walls being substantially straight and connected together at their respective ends so as to form a generally square or rectangular cross-section shape of the swaged portion; and 
 a respective local deformation defined in each of the four walls, wherein a perimeter of the swaged portion is defined entirely by the four walls and the four local deformations. 
   
     
     
         16 . The structure as recited in  claim 15 , wherein each wall has two straight portions, one straight portion adjoining either side of the local deformation in that wall, and each straight portion adjoining another straight portion of another of the walls. 
     
     
         17 . The structure as recited in  claim 15 , wherein one of the local deformations protrudes inwardly from an exterior surface of the swaged portion. 
     
     
         18 . The structure as recited in  claim 15 , wherein the swaged portion is substantially hollow, or substantially solid. 
     
     
         19 . The structure as recited in  claim 15 , wherein when the swaged portion is fully received in a corresponding flared portion of another structure, the entire perimeter of the swaged portion, except for the four local deformations, is in contact with corresponding walls of the flared portion. 
     
     
         20 . The structure as recited in  claim 15 , wherein the swaged portion includes a first end and a second end, and a perimeter of the first end is relatively smaller than a perimeter of the second end.