Friction stir interlocking of dissimilar materials

Abstract

A method for solid state joining of dissimilar materials using a friction stir welding device wherein a pin is inserted through an aperture defined in a first material and a second material to hold the materials together and then held in place by friction stir welding a portion of the pin to a material adjacent said pin, or by friction stir welding a cap or plug that holds the pin in place to the adjacent material. The result is a connection or join wherein the central portion of the pin is not friction stir welded but the portions holding the pin in place (the ends or caps) generally are.

What is claimed is: 
     
         1 . A method for solid state joining of dissimilar materials using a friction stir welding device comprising the steps of:
 inserting an insert within an aperture defined in a first material and a second material, and   friction stir welding a portion of said insert to a material adjacent to said pin.   
     
     
         2 . The method of  claim 1  wherein said first material is aluminum. 
     
     
         3 . The method of  claim 1  wherein said second material is steel. 
     
     
         4 . The method  claim 1  wherein said second material is a carbon reinforced composite. 
     
     
         5 . The method of  claim 1  wherein said first material is configured in to a C-shape and said second material is embodied in an insert configured to fit within said C-shaped material. 
     
     
         6 . The method of  claim 4  wherein said insert is a pin has two ends and is friction stir welded in each end to the first material. 
     
     
         7 . The method of  claim 5  wherein said first material is aluminum and said second material is steel. 
     
     
         8 . The method of  claim 5  wherein said first material is steel and said second material is aluminum. 
     
     
         9 . A method for solid state joining of dissimilar materials using a friction stir welding device comprising the steps of:
 inserting a pin through an aperture defined in a first material and a second material;   capping at least one end of pin with a cap material;   and friction stir welding said cap to a material adjacent said cap.   
     
     
         10 . The method of  claim 9  wherein said first material is aluminum. 
     
     
         11 . The method of  claim 9  wherein said second material is steel. 
     
     
         12 . The method  claim 9  wherein said second material is a carbon reinforced composite. 
     
     
         13 . The method of  claim 9  wherein said first material is configured in to a C-shape and said second material is embodied in an insert. 
     
     
         14 . The method of  claim 9  wherein said first material is aluminum and said second material is steel. 
     
     
         15 . The method of  claim 9  wherein said first material is steel and said second material is aluminum. 
     
     
         16 . A method of joining a first metal material to a carbon reinforced composite comprising the steps of overcasting the metal material over the carbon reinforced composite material. 
     
     
         17 . A method of joining a metal material to a carbon reinforced composite comprising the steps of inserting a metal insert within the carbon reinforced composite during fabrication of the carbon reinforced composite and then friction stir welding a second piece of metal to the metal insert or inserts that were embedded during the fabrication of the said composite. 
     
     
         18 . A joint comprising:
 a first material connected to a second material by a pin passing through said first material and said second material, said pin held in place by friction stir welded portions.   
     
     
         19 . The joint of  claim 16  wherein the ends of the pin are friction stir welded to a material adjacent the end of said pin. 
     
     
         20 . The joint of  claim 16  where in the pin is held in place by at least one cap that is friction stir welded to the material adjacent said cap.