Certification of a weld produced by friction stir welding

• US 8,544,714 B1
• Filed: 11/15/2012
• Issued: 10/01/2013
• Est. Priority Date: 11/15/2012
• Status: Active Grant

• Current Assignee: Fluor Technologies Corporation (Fluor Corporation)
• Original Assignee: Fluor Technologies Corporation (Fluor Corporation)
• Inventors: Grant, Glenn J., Obaditch, Chris
• Primary Examiner(s): STONER, KILEY SHAWN
• Application Number:
  US13/677,586
• Time in Patent Office: 320 Days
• Field of Search: None
• US Class Current: 228/102
• CPC Class Codes: B23K 20/123 Controlling or monitoring the welding process
• CPC Class Codes: B23K 20/124 at the beginning or at the end of a weld
• CPC Class Codes: B23K 31/125 Weld quality monitoring

Abstract

Methods, devices, and systems for providing certification of friction stir welds are disclosed. A sensor is used to collect information related to a friction stir weld. Data from the sensor is compared to threshold values provided by an extrinsic standard setting organizations using a certification engine. The certification engine subsequently produces a report on the certification status of the weld.

Claims

1. A method of acquiring certification-related information related to a weld, comprising:

utilizing a friction stir welding device to produce a weld that joins a first workpiece and a second workpiece;

operating a sensor to derive sensor data that represents at least one characteristic of the weld prior to disassociating the device with the first and second workpieces;

storing the sensor data in an electronic storage medium;

configuring a certification engine to compare the sensor data to certification data, wherein the certification data represent at least one threshold weld characteristic defined by an extrinsic standard setting organization; and

reporting a certification status of the weld to a user.

2. The method of claim 1, further comprising generating a report relating the sensed characteristic to the threshold characteristic.

3. The method of claim 1, wherein the threshold characteristic is a friction stir welding standard.

4. The method of claim 3, wherein the threshold characteristics are derived from a ISO 25239-5:

2011 code.

5. The method of claim 3, wherein the threshold characteristics correspond to an AWS D17.3/D17.3M:

2010 code.

6. The method of claim 1, wherein there is a time lag of less than about 60 minutes between producing the weld and operating the sensor.

7. The method of claim 6, wherein the time lag is less than about 10 minutes.

8. The method of claim 6, wherein the time lag is less than about 1 minute.

9. The method of claim 1 wherein the step of operating the sensor occurs prior to a maximum temperature of the weld falling below about 100°

C.

10. The method of claim 1, further comprising using a rotating friction stir welding tool to produce the weld and using the sensor to provide a signal from which at least one of the sensor data is derived.

11. The method of claim 10, further comprising having the sensor trail the friction stir welding tool by no more than 1 meter during the step of operating the sensor.

12. The method of claim 10, further comprising having the sensor trail the friction stir welding tool by no more than 4 radian during the step of operating the sensor.

13. The method of claim 10, further comprising having the sensor trail the friction stir welding tool by a fixed distance during the step of operating the sensor.

14. The method of claim 10, wherein the sensor data comprises load data of the friction stir welding tool.

15. The method of claim 10, wherein the sensor data comprises temperature data of the friction stir welding tool and temperature data of the weld.

16. The method of claim 1, further comprising coupling the sensor to an arm of the friction stir welding device.

17. The method of claim 1, wherein a portion of the step of operating the sensor occurs when the rotating pin is less than about 10 meters from the weld.

18. The method of claim 1, wherein the at least one characteristic of the weld is selected from the group consisting of conductivity, density, permittivity, magnetic permeability, optical characteristic, radiolucency, temperature, and temperature profile.

19. The method of claim 1, further comprising at least partially positioning the sensor inside the weld.

20. A method of issuing a certification with respect to the weld of claim 1, comprising issuing the certification prior to separating the friction stir welding device from the first and second workpieces.

21. A method of issuing a certification with respect to the weld of claim 1, comprising issuing the certification prior to moving the friction stir welding device more than about 10 meters from the weld.

22. A friction stir welding device for producing a weld to join a first workpiece and a second workpiece, comprising:

a first arm that couples with a friction stir welding tool;

a second arm that couples with a sensor, wherein the sensor produces a signal comprising sensor data;

a control system that controls movement of the first arm and second arm;

a certification engine that receives the signal and compares the sensor data to a certification data, wherein the certification data represent at least one threshold weld characteristic defined by an extrinsic standard setting organization; and

a reporting device coupled with the certification engine and configured to report a certification status of the weld to a user.