Method of repairing a crack in a component utilizing friction stir welding

• US 7,000,303 B2
• Filed: 10/24/2002
• Issued: 02/21/2006
• Est. Priority Date: 10/24/2002
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Talwar, Rajesh, Perez, Rigoberto
• Primary Examiner(s): Bryant, David P.
• Assistant Examiner(s): Cozart, Jermie E.
• Application Number:
  US10/279,950
• Publication Number:
  US 20030217452A1
• Time in Patent Office: 1,216 Days
• Field of Search: 294/020.7, 294/020.9, 294/021.3, 294/021.6, 294/020.1, 294/020.4, 294/020.6, 294/021.1, 294/021.2, 294/021.4, 228/112.1, 228/119, 228/2.1
• US Class Current: 29/402.01
• CPC Class Codes: B23K 20/122 using a non-consumable tool, e.g. friction stir welding
• CPC Class Codes: B23K 20/1295 Welding studs
• CPC Class Codes: B23P 2700/01 Aircraft parts
• CPC Class Codes: B23P 6/00 Restoring or reconditioning objects straightening or restoring form of sheet metal, metal rods, metal tubes, metal profiles, or specific articles made therefrom B21D1/00, B21D3/00; repairing defective or damaged objects by casting techniques B22D19/10
• CPC Class Codes: B23P 6/04 Repairing fractures or cracked metal parts or products, e.g. castings
• CPC Class Codes: B64F 5/40 Maintaining or repairing aircraft
• CPC Class Codes: Y10T 29/49718 Repairing
• CPC Class Codes: Y10T 29/49723 including reconditioning of part
• CPC Class Codes: Y10T 29/49728 and by a metallurgical operation, e.g., welding, diffusion bonding, casting
• CPC Class Codes: Y10T 29/49732 by attaching repair preform, e.g., remaking, restoring, or patching
• CPC Class Codes: Y10T 29/49734 and removing damaged material
• CPC Class Codes: Y10T 29/49735 Mechanically attaching preform with separate fastener
• CPC Class Codes: Y10T 29/49739 Mechanically attaching preform by separate fastener
• CPC Class Codes: Y10T 29/49742 Metallurgically attaching preform
• CPC Class Codes: Y10T 29/49746 by applying fluent material, e.g., coating, casting

Abstract

A method of repairing a crack (14) in a component (12). The method includes preparing a surrounding surface (22) of the crack (14) for repair and welding a first portion (24) of the component (12) on a first side (26) of the crack (14) to a second portion (28) of the component (12) on a second side (30) of the crack (14) to form a fused crack area (50). The method may also include applying a patch (78) over the fused crack area (50) for additional strength.

Claims

1. A method of repairing a crack in a component comprising:

preparing a surrounding surface of the crack for repair;

friction stir welding a first portion of the component on a first side of the crack to a second portion of the component on a second side of the crack to form a fused crack area;

inserting a temporary plug into an existing hole of the component;

friction stir welding said crack

disengaging a friction stir welding tool in a center of a partial exit hole; and

removing said temporary plug from the component.

2. A method as in claim 1 further comprising

inserting a non-consumable fastener in at least one exit hole in the component.

3. A method as in claim 1 comprising:

initiating friction stir welding at a first end of the crack;

friction stir welding to at least a second end of the crack;

drilling a through hole in the component to provide a finished hole; and

inserting a non-consumable fastener in said finished hole.

4. A method as in claim 1 further comprising

drilling a through hole in the component to provide an enlarged or extended finished hole.

5. A method as in claim 1 further comprising:

applying a patch over said fused crack area; and

coupling said patch to the component.

6. A method as in claim 1 wherein applying a patch comprises applying a composite patch.

7. A method as in claim 1 wherein applying a patch comprises applying a metallic patch.

8. A method as in claim 1 wherein coupling said patch comprises bonding said patch to said component via an adhesive material.

9. A method as in claim 1 wherein coupling said patch comprises fastening said patch to said component via a plurality of fasteners.

10. A method as in claim 1 further comprising continuing friction stir welding of the component to an edge of the component using additional tab material.

11. A method as in claim 1 further comprising fusing at least one hole in the component via a retractable pin tool.

12. A method as in claim 1 further comprising friction stir plug welding at least one hole in the component.

13. A method of repairing a crack in a component of an aircraft comprising:

preparing a surrounding surface of the crack for repair;

friction stir welding a first portion of the component on a first side of the crack to a second portion of the component on a second side of the crack to form a fused crack area;

applying a patch over said fused crack area;

coupling said patch to the component;

plug welding at least one hole in the component;

inserting a temporary plug into an existing hole of said at least one hole;

friction stir welding said crack;

disengaging a friction stir welding tool in a center of a partial exit hole; and

removing said temporary plug from the component.

14. A method as in claim 13 wherein applying a patch comprises applying a patch formed of a material selected from at least one of a composite material and a metallic material.

15. A method as in claim 13 wherein friction stir welding comprises utilizing a double-sided tool to apply equal and opposite load on sides of the component.

16. A method of repairing a crack in a component of an aircraft comprising:

preparing a surrounding surface of the crack for repair;

friction stir welding a first portion of the component on a first side of the crack to a second portion of the component on a second side of the crack to form a fused crack area;

applying a patch over said fused crack area;

coupling said patch to the component; and

inserting a fastener in at least one exit hole in the component.

17. A method as in claim 16 wherein applying a patch comprises applying a patch formed of a material selected from at least one of a composite material and a metallic material.

18. A method as in claim 16 wherein friction stir welding comprises utilizing a double-sided tool to apply equal and opposite load on sides of the component.

19. A method as in claim 16 further comprising plug welding at least one hole in the component.

20. A method of repairing a crack in a component of an aircraft comprising:

preparing a surrounding surface of the crack for repair;

inserting a temporary plug into an existing hole;

friction stir welding a first portion of the component on a first side of the crack to a second portion of the component on a second side of the crack to form a fused crack area;

disengaging a friction stir welding tool in a center of a partial exit hole;

removing said temporary plug from the component;

applying a patch over said fused crack area; and

coupling said patch to the component.

21. A method as in claim 20 further comprising

drilling a through hole at an end of said fused crack area to provide a non-plugged finished through hole.