CONTROLLED SPEED FRICTION STIR TOOL PROBE BODIES HAVING NON-LINEAR, CONTINUOUS, MONOTONICALLY-DECREASING CURVED AXIAL PROFILES AND INTEGRATED SURFACE FEATURES

摘要

A friction stir processing tool and method for manufacturing the same are provided. The tool includes a non-consumable, interchangeable friction stir probe body. The tool includes a material flow path defined by an outer surface of a probe body, which has a non-linear, continuous, monotonically-decreasing axial profile. The probe body is adapted to engage a workpiece material to perform a friction stir process by rotating about an axis thereof thereby directing a weld material toward a distal end of the probe body along the flow path. The flow path varies in pitch as the lateral cross-sectional dimension of the probe body decreases toward the distal end thereby causing the weld material to maintain a controlled speed as it travels along the flow path. Geometric surface features such as threads, helical grooves, ridges, flutes, and/or flats, integrated with the probe body may define the flow path.