Patent ID: 12251772

DETAILED DESCRIPTION

In the attached drawings, like reference numerals designate corresponding elements throughout. In particular, to simplify the description, the reference numerals used inFIGS.1A-1Care used again in connection with the description of the invention hereinafter, except that each such reference numeral is raised by 100 (or by whole number multiples thereof, as the case may be), where the elements correspond to elements illustrated inFIGS.1A-1C.

Reference is first made toFIGS.2A-3Ito describe an embodiment of a method in accordance with the invention for at least partially filling one or more openings112in a workpiece110made of a metal. As can be seen, for instance, inFIG.3G, the opening112is at least partially defined by one or more opening walls116having one or more opening wall surfaces118. In one embodiment, the method preferably includes providing an insert120including an insert material that is metallically bondable with the metal. Those skilled in the art would also be aware of materials that are metallically bondable with each other.

As will be described, the insert120preferably is formed to at least partially fit into the opening112. It is preferred that the insert120has one or more insert engagement surfaces122(FIG.3G) that are formed for engagement with the opening wall surface(s)118.

Preferably, the opening wall surface118is heated in a first non-oxidizing atmosphere to a hot working temperature. As will also be described, when the opening wall surface118is heated to the hot working temperature, the opening wall surface118is plastically deformable. It is also preferred that the insert engagement surface122is heated in a second non-oxidizing atmosphere to the hot working temperature. When the insert engagement surface122is also heated to the hot working temperature, the insert engagement surface122is also plastically deformable.

The hot working temperature is below the metal's melting temperature. It will be understood that the “hot working temperature”, for the purposes hereof, may in fact be a range of temperatures. Those skilled in the art would be aware of suitable hot working temperatures for any particular metals, and suitable non-oxidizing atmospheres therefor.

Preferably, the insert120is subjected to an engagement motion, to move the insert engagement surface(s)122relative to the opening wall surface(s)118. As will be described, the engagement motion may be as oscillating or vibrating motion. While the insert120is subjected to the engagement motion, and while the insert engagement surface122and the opening wall surface118are at the hot working temperature, the insert120preferably is also subjected to a translocation motion, to move the insert120at least partially into the opening112, to engage the insert engagement surface(s)122with the opening wall surface(s)118.

As will also be described, the insert120preferably is simultaneously subjected to both the engagement motion and the translocation motion, to engage the moving insert engagement surface(s)122with the opening wall surface(s)118, to cause plastic deformation of the opening wall surface(s)118and of the insert engagement surface(s)122as they engage each other, for at least partially creating a metallic bond between the insert120and the workpiece110. Finally, the insert120and the workpiece110are allowed to cool, to solidify the insert120and the workpiece110together.

Those skilled in the art would be aware that the opening wall surface(s)118and the insert engagement surface(s)122should be suitably prepared (e.g., cleaned) prior to their heating and subsequent engagement. Those skilled in the art would also be aware of suitable surface preparation techniques.

In the example illustrated inFIG.3G, the opening112is at least partially defined by two opening wall surfaces118. The opening wall surfaces118may be heated to the hot working temperature by any suitable means. For instance, inFIG.2A, two opening surface heating elements124are shown as being located proximal to the two opening wall surfaces118respectively. In addition, two insert heating elements126are also shown inFIG.2A, for heating the insert engagement surfaces122respectively to the hot working temperature.

Once the opening wall surface heating elements124have heated the opening wall surfaces118to the hot working temperature, they are removed, as indicated by arrows “A1”, “A2” (FIGS.2A,3A). Also, once the insert engagement surfaces122have been heated to the hot working temperature, the insert heating elements126are removed, as indicated by arrows “B1”, “B2” (FIGS.2A,3A).

The insert120, while subjected to the engagement motion (as indicated by arrows “Y” inFIG.3D), is moved (i.e., translocated) into the opening118, as indicated by arrow “D” inFIGS.3D and3GA. As noted above, the hot working temperature is the temperature at which the insert engagement surface122and the opening wall surface118are subject to plastic deformation thereof. At the same time as the insert120is subjected to the engagement motion, the insert120is translocated to engage the workpiece110. Upon engagement, the insert engagement surface122engages the opening wall surface118. When the insert120engages the workpiece110, the insert120is still subjected to the engagement motion, in order to plastically deform the insert engagement surface122and the opening wall surface118. In a short time period immediately following the initial engagement of the insert engagement surface122with the opening wall surface118, the insert120continues to move (i.e., is subjected to the engagement motion) relative to the workpiece110. It will be understood that the engagement is effected with considerable force, in order to achieve metallic bonding.

The engagement of the insert engagement surface122with the opening wall surface118, both of which are at the hot working temperature, results in a zone of material at the insert engagement and opening wall surfaces122,118in which the insert120and the workpiece110are metallically bonded with each other. Such bonding is the result of the engagement force applied, and simultaneous engagement motion of the insert relative to the workpiece while the engaged surfaces118,122are at the hot working temperature.

The method results in a workpiece and insert that are fused together to form a product in which heat-affected zones are absent. The process of the invention appears to result in a metallically bonded zone “Z” (FIGS.3E,3F) at which the insert and the workpiece are fused together, and in which bonded zone the metal has a uniform crystalline microstructure. As disclosed, e.g., in U.S. Pat. No. 6,637,642, the metal is heated to the temperature (the hot working temperature) at which the metal is plastically deformable. It is also believed to be important, in order to achieve a uniform crystalline microstructure in the bonded zone, that the metal not be melted during the heating and engagement steps of the process.

It will be understood that the metal of the workpiece and the metal of the insert may be any suitable materials that may be fused together by the method of the invention, e.g., alloys or metal elements, as the case may be. For instance, the metals that are fused together may include steel, aluminum, titanium, zirconium, Inconel™ and Hastelloy™. Due to the heat and shear/forging pressure that is applied, the material in the bonded zone has a uniform crystalline micro structure, which is relatively strong. For instance, it has been determined that, where the insert and the workpiece are made of steel, the steel in the bonded zone is bainitic.

The insert heating elements126and the opening surface heating elements124may be any suitable heating elements that can provide sufficient heat. Those skilled in the art would be aware of suitable heating elements. The heating elements124,126preferably are configured for generally uniform heating of the opening wall surface(s)118and the insert engagement surface(s)122respectively. As can be seen, for example, inFIG.2A, the heating elements124,126preferably are removable, so that, once the surfaces118,122have reached the hot working temperature, the heated insert engagement surface(s)122may engage the heated opening wall surface(s)118. Preferably, the removal of the heating elements, and the subsequent engagement of the insert and the workpiece, all take place within a relatively short period of time, to minimize the extent of heat loss from the surfaces118,122prior to their engagement with each other.

It is preferred that the opening wall surface118is uniformly heated (or substantially uniformly heated) to the hot working temperature. To achieve this uniformity, it is also preferred that the opening wall116is uniformly heated to the hot working temperature to a first distance128from the opening wall surface118in the opening wall116(FIG.3G). Those skilled in the art would be able to determine a suitable first distance.

Preferably, the insert engagement surface122is also uniformly heated (or substantially uniformly heated) to the hot working temperature. To achieve this uniformity, it is also preferred that the insert120is uniformly heated to the hot working temperature to a second distance130from the insert engagement surface122in the insert120(FIG.3G). Those skilled in the art would be able to determine a suitable second distance.

As described above, the engagement motion of the insert120is intended to continue when, and after, the insert engagement surface122engages the opening wall engagement surface118, to cause plastic deformation of each of the hot insert engagement surface122and the hot opening wall surface118. It is believed that, due to the engagement motion and the force exerted to engage the insert with the workpiece, the materials of the insert engagement surface122and the opening wall surface118are commingled or mixed together, to a very small extent. To achieve this, the engagement motion continues for a short time after the surfaces118,122engage each other. The engagement motion may be any suitable motion. For example, any repetitive motion of the insert120relative to the workpiece110may be suitable. For instance, in one embodiment, the engagement motion preferably is an oscillating motion relative to the workpiece110.

As an example, as can be seen inFIG.3D, the insert's engagement motion may be longitudinal (i.e., back and forth), along an elongate opening112, as the insert is moved into the opening112by the translocation motion. As noted above, the longitudinal engagement motion preferably continues for a short time period after the initial engagement of the insert with the opening wall, i.e., until the insert and the workpiece become bonded together. Another example of engagement motion is illustrated inFIG.3G, in which the insert120is moved axially (i.e., back and forth, aligned with the direction of translocation) as the insert120is moved into the opening by the translocation motion (indicated by arrow “D”). It will be understood that, in this example also, the engagement motion preferably continues for a short time period after the initial engagement of the insert with the opening wall, i.e., until the insert and the workpiece become bonded together.

Alternatively, in another embodiment, the oscillating motion preferably is a linear motion of the insert, in which the insert is moved linearly relative to the workpiece, e.g., in any suitable direction. The oscillating motion may alternatively describe any suitable pattern, e.g., an arc or a partial ellipse.

In another alternative embodiment, the engagement motion preferably is a rotation of the insert120relative to the workpiece110, e.g., about an axis “X” of the insert120(FIG.3A). Alternatively, the engagement motion may be a vibrating motion relative to the workpiece.

As can be seen, e.g., inFIG.3D, in one embodiment, the insert120preferably is subjected to an engagement motion in which the insert120is moved longitudinally along the opening112, as indicated by arrow “G” inFIG.3D. The arrow “G” is double-ended to indicate an oscillating longitudinal motion. In this example, the direction of the translocation motion is orthogonal (or substantially orthogonal) to the back-and-forth directions of the engagement motion.

In one embodiment, the opening wall surface118preferably is planar, and it is preferred that the insert engagement surface122also is planar (FIG.3G). It will be understood that the opening wall engagement surface118and the insert engagement wall surface122preferably are formed to engage each other when the insert120is at least partially inserted into the opening112. Preferably, the insert engagement surface122and the opening wall surface118are formed to cooperate with each other to locate the insert120at least partially in the opening112so that the respective areas of the surfaces are substantially engageable with each other.

As illustrated inFIGS.2A,3A,3E,3F, and3G, it is preferred that the translocation motion is in a predetermined linear direction into the opening112. As examples, the direction of the translocation motion is indicated by arrow “D” inFIGS.2A,3A,3E,3F, and3G. Preferably, the opening wall surface118is located at a predetermined angle θ relative to the predetermined linear direction of the translocation motion (FIG.3G). The predetermined angle may be any suitable angle. For instance, inFIG.3G, the angle θ defined by the opening wall surfaces118relative to the insert's direction of translocation motion is approximately 15°.

Those skilled in the art would appreciate that, inFIGS.2A-2C, the opening wall surfaces118preferably are substantially parallel with the insert engagement surfaces122that are to be engaged therewith. It will be understood that in the embodiment illustrated inFIGS.2A-2D, the insert120preferably is slightly wider than the opening112. That is, the width “W1” of the insert120identified inFIG.2Apreferably is slightly wider than the width “W2” of the opening112, when the surfaces are heated to the hot working temperature.

As can be seen, e.g., inFIG.2B, in one embodiment, one or more clamps132A,132B preferably exert inwardly-directed pressure (schematically represented by arrows “E1”, “E2”) onto the workpiece110, to maintain the shape of the workpiece, and to hold the workpiece stationary.

As can also be seen, e.g., inFIGS.2A,2B,3A,3B,3F, and3G, the translocation motion preferably is in the predetermined linear direction, into the opening112. As illustrated inFIGS.2B,3B,3F, and3G, the translocation movement of the insert120may be, for example, inwardly (as indicated by arrow “D”), or outwardly (as indicated by arrow “F”).

Once the insert120is positioned at least partially in the opening112and the insert has bonded with the workpiece, one or more portions134thereof may extend beyond the opening wall surface(s)118of the workpiece that the insert120has bonded with (FIG.2C). In this situation, the portions134may be cut off or otherwise removed, using any suitable means.

It will be understood that, during the engagement of the insert engagement surface122and the opening wall surface118, a small portion of the material that is plastically deformed may be extruded from the insert and/or the workpiece, along an exposed part of the insert and/or the workpiece at the surfaces118,122. Depending on the specifications that the bonded or fused insert and the workpiece are required to meet, the extruded material, once cooled, may be required to be removed. In practice, however, such removal may be difficult, and time-consuming.

Those skilled in the art would appreciate that the insert120may have any suitable configuration. In one embodiment, illustrated inFIG.3C, the insert120preferably extends between an inner end136and an outer end138thereof, and the insert120preferably also includes one or more chamfered insert surfaces140located proximal to the insert engagement surfaces122, at one or more of the inner and outer ends136,138. The chamfered insert surfaces140preferably are formed in order to minimize the amount of extruded material that may extend beyond the insert120and/or the workpiece110at inner and/or outer sides of the insert, once the insert and the workpiece are bonded together.

As can also be seen inFIG.3C, each of the opening wall surfaces118preferably extends between an internal end142and an external end144. It is preferred that the workpiece110includes one or more chamfered workpiece surfaces146located proximal to the opening wall surface(s)118at one or more of the internal and external ends142,144. The chamfered workpiece surfaces146preferably are formed in order to minimize the amount of extruded material that may extend beyond the insert120and/or the workpiece110at inner and/or outer sides of the insert.

The chamfered surfaces140,146define spaces into which any plastically deformed material that is squeezed out as the insert is engaged with the workpiece may enter, so that such material is not extruded into the interior of the tube workpiece, or alternatively, not extruded onto the exterior surface of the tube workpiece.

In one embodiment, it is preferred that the insert120includes one or more notches148formed at the inner end136, to minimize the amount of extruded material that may protrude into the interior of the tube workpiece.

The workpiece110may include two or more layers of respective metals. For example, as illustrated inFIGS.2D and3I, the workpiece110may include a first layer180of a first metal, and a second layer182of a second metal. It will be understood that, to form the workpiece110, the layers180,182may be fused together using any suitable method.

Where the workpiece110includes two or more layers of respective metals, it is preferred that the insert120also includes layers184,186to fuse or bond with the layers180,182respectively. When the insert120is at least partially located in the opening, the layers184,186are metallically bondable with the layers180,182respectively (FIGS.2E,3J). For instance, as illustrated inFIGS.2D and2E, and inFIGS.31and3J, in one embodiment, the insert120preferably includes the layers184,186of steel and copper respectively. It is also preferred that the layers184,186are formed so that, when the insert120is at least partially located in the opening112, the layers184,186are substantially aligned with the corresponding layers180,182of steel and copper respectively in the workpiece110.

Heating elements124′,126′ preferably are used to heat the opening wall surface118and the insert engagement surface122respectively. The heating elements124′ preferably include first and second parts189,190for heating the first and second layers180,182respectively. Also, the heating elements126′ preferably include first and second parts191,192for heating the layers184,186of the insert120respectively.

In an alternative embodiment illustrated inFIGS.4A-4C, the method of the invention is for at least partially attaching a tube250to a workpiece210made of a metal, to at least partially align the tube250with one or more openings212in the workpiece210. The tube250is also made of a metal that is bondable with the metal of the workpiece210(i.e., preferably the same metal). The opening212is at least partially defined by one or more opening walls216having one or more opening wall surfaces218(FIG.4B). The method preferably includes forming one or more tube engagement surfaces252on the tube250that are configured for engagement with the opening wall surface(s)218. Preferably, the opening wall surface218is heated in a first non-oxidizing atmosphere to a hot working temperature, at which the opening wall surface218is plastically deformable. It is also preferred that the tube engagement surface252is heated in a second non-oxidizing atmosphere to the hot working temperature, at which the tube engagement surface252is plastically deformable. Next, the tube250preferably is subjected to an engagement motion, to move the tube engagement surface252relative to the opening wall surface218.

It will be understood that heating elements and clamps are omitted fromFIGS.4A-5Bto simplify the illustration.

While the tube250is subjected to the engagement motion, and while the tube engagement surface252and the opening wall surface218are at the hot working temperature, the tube250preferably is also subjected to a translocation motion to move the tube250at least partially into the opening212, for engaging the tube engagement surface252with the opening wall surface218while the tube is subjected to the engagement motion. As described above, this causes plastic deformation of the opening wall surface218, and plastic deformation of the tube engagement surface252also as they engage each other, for at least partially creating a metallic bond between the tube250and the workpiece210. Finally, the tube250and the workpiece210are allowed to cool, to solidify the tube250and the workpiece210together.

As can be seen inFIGS.4A-4C, the workpiece210may be, for example, a flat sheet of metal, e.g., steel. InFIG.4B, the tube250and the workpiece210are shown shortly before engagement of the tube250and the workpiece210. It will be understood that the heating elements and other elements needed to implement the method of the invention (e.g., clamps) are omitted fromFIG.4Bfor clarity of illustration.

The engagement motion may be, for example, a repeated or oscillating rotational motion of the tube250about its axis “2X”, as indicated by arrows “2Y1” and “2Y2” inFIG.4A. The translocation motion is in the direction indicated by arrow “2D” inFIG.4B. The translocation motion preferably is coaxial with the axis “2X”.

InFIG.4B, it can be seen that, in one embodiment, the tube engagement surface252preferably is planar, and positioned at a selected angle relative to the direction of the translocation motion. Also, the opening wall surface218preferably is planar, and positioned at the selected angle relative to the direction of the translocation motion.

As described above, while the tube250is subjected to the engagement motion, it is simultaneously moved in the direction indicated by arrow “2D”, to engage the tube engagement surface252with the opening wall surface218. Preferably, after the tube engagement surface252initially engages the opening wall surface218, the tube250is still moving in accordance with the engagement motion. At that point in the process, the tube250continues to be pressed against the workpiece210in the direction indicated by arrow “2D”, while the insert250is subject to the engagement motion. This results in the plastic deformation of the tube engagement surface252and the opening wall surface218, resulting in the tube250fusing with the workpiece210, as described above.

The tube250and the workpiece210rapidly cool after initial engagement, and the engagement motion ceases shortly after the initial engagement because the tube250and the workpiece210rapidly bond together, preventing further engagement motion.

InFIGS.5A and5B, a tube350is shown being bonded with a workpiece310. The tube350defines an axis “3X” thereof. The tube350is aligned with an opening312. InFIG.5A, the tube engagement surface352and the opening wall surface318can be seen, prior to their engagement. It will be understood that the heating elements and other elements (e.g., clamps) needed to implement the method of the invention are omitted fromFIG.5Afor clarity of illustration. It will also be understood that the tube350is subjected to the engagement motion while the tube engagement surface352and the opening wall surface318are both heated, in non-oxidizing atmospheres, to the hot working temperature. The engagement motion may be, for example, an oscillating rotational motion of the tube350about its axis “3X”. The tube350is then moved in the translocation motion direction (indicated by arrow “3D”), while still subjected to the engagement motion.

The tube engagement surface352and the opening wall surface318are subjected to plastic deformation upon their engagement and shortly thereafter, to form a metallic bond between the tube350and the workpiece310.

The workpiece310may be, for example, a body of a manifold, and the tube350may be one of several tubes (not shown) secured to the body, to form the manifold.

In another alternative embodiment illustrated inFIGS.6A-6J, the method of the invention is for repairing a workpiece410that includes a preselected region411thereof (FIG.6A). The preselected region411may be any region in which an insert is to be inserted, for example, a defective or worn region of the workpiece410. Preferably, the method includes forming one or more opening walls416in the workpiece410at least partially around the preselected region411to produce a remainder segment456of the workpiece410. InFIG.6A, a dashed line416′ indicates the location of the opening wall416in relation to the preselected region411.

It will be understood that, to form the opening walls416, material may be removed from peripheral regions457(FIG.6A) around the preselected region411of defective or worn (e.g., corroded) material of the workpiece410. The opening wall416preferably includes one or more opening wall surfaces418(FIG.6C) defining at least one initial opening412. As will be described, the opening walls416preferably are formed to define the shape of the initial opening412so that an insert458is receivable in the opening412. Preferably, the opening412includes or encompasses or coincides with the preselected region411.

The preselected region411may be any part of the workpiece that is to be replaced. For instance, the preselected region411may be a part of the workpiece that has corroded or weakened over time, or that includes pitting or cracking resulting from use. The preselected region411may alternatively include defects formed when the workpiece was manufactured.

Preferably, the insert458is metallically bondable with the remainder segment456. It is preferred that the insert458is formed to at least partially fit into the opening412, as shown inFIGS.6C and6E. The insert458preferably has one or more insert engagement surfaces452formed for engagement with the opening wall surface418(FIG.6C).

It is also preferred that an inert (non-oxidizing) atmosphere is provided that covers the insert458, one or more heating elements, and the remainder segment456. Those skilled in the art would appreciate that the non-oxidizing atmosphere preferably is held in position by a suitable covering or container (not shown). The covering or container is omitted from the drawings for clarity of illustration.

Preferably, one or more heating elements are positioned in respective predetermined positions relative to the insert engagement surface452and to the opening wall surface418. As can be seen inFIG.6C, one or more first heating elements424preferably are positioned in predetermined positions relative to the opening wall surface418, and one or more second heating elements426preferably are positioned in predetermined positions relative to the insert engagement surface452.

Next, the heating elements424,426are energized, to heat a remainder segment heated portion465and an insert heated portion467to a hot working temperature. The remainder segment heated portion465and the insert heated portion467are plastically deformable at the hot working temperature. It will be understood that the heating elements424,426preferably are configured for induction heating of the remainder segment heated portion465and the insert heated portion467.

As can be seen inFIG.6C, the remainder segment heated portion465extends from the opening wall surface418into the remainder segment456. Similarly, the insert heated portion467extends from the insert engagement surface452into the insert458.

It will also be understood that the widths of the respective heated portions465,467are exaggerated inFIG.6C, for clarity of illustration. In practice, the heated portions465,467are extremely thin, e.g., approximately five millimeters.

Once the remainder segment heated portion465and the insert heated portion467are at the hot working temperature, the heating elements424,426preferably are removed, to enable the insert458to be moved to engage the remainder segment456.

After the heating elements have been removed, and while the remainder segment heated portion465and the insert heated portion467are at the hot working temperature, the insert458preferably is subjected to an engagement motion, to move the insert engagement surface452relative to the opening wall surface418. It will be understood that the insert's engagement motion may be any suitable motion thereof, relative to the remainder segment456. For example, the insert458may be oscillated in the directions indicated by arrow “4Y” inFIG.6D.

Preferably, while the insert458is subjected to the engagement motion, and while the remainder segment heated portion465and the insert heated portion467are at the hot working temperature, the insert458is also subjected to a translocation motion, to push the insert458at least partially into the initial opening412. The direction of the translocation motion is indicated by arrow “4D” inFIG.6C.

The insert458is moved into the opening412to engage the insert engagement surface452with the opening wall surface418. While the insert is subject to the engagement motion, and while the remainder segment heated portion465and the insert heated portion467are at the hot working temperature, the insert engagement surface452is pressed against the opening wall surface418, to cause plastic deformation of the remainder segment heated portion465and the insert heated portion467, for creating a metallic bond between the insert458and the remainder segment456. The direction in which the insert458is pressed against the remainder segment456is indicated by arrow “4G” inFIG.6E.

Finally, the first insert458and the remaining portion456of the workpiece410preferably are permitted to cool, to bond or fuse the insert458and the remainder segment456together.

As can be seen inFIG.6D, once the insert458and the remainder segment456are bonded together, the initial opening412is not fully occupied by the first insert458. In these circumstances, the remainder segment456and the insert458form an incomplete workpiece460(FIG.6D). The incomplete workpiece460, as illustrated inFIG.6D, includes a body481and unfilled parts “J1”, “J2”, of the initial opening412that remain unoccupied after the first insert458and the remainder segment456of the workpiece have been fused together, i.e., metallically bonded together, as described above. When the first insert458and the remainder segment456are bonded together, they form the body481.

In the example illustrated inFIG.6D, there are two unfilled parts “J1”, “J2”, located at each end of the insert458. Based on the description above, it can be seen that the engagement motion of the insert458in the initial opening412may be an oscillation in the directions indicated by arrow “4Y” inFIG.6D. Those skilled in the art would appreciate that, when the insert458becomes fused or bonded to the remainder segment456, depending on the position of the insert458at that point, the parts “J1”, “J2” of the initial opening412may remain unfilled. It will be understood that the insert458may become bonded to the remainder segment456when it is at one end of the initial opening412, and in these circumstances, only one unfilled part may be defined.

Those skilled in the art would appreciate that, when the first insert engagement surface452and the opening wall surface418are engaged with each other and plastically deformed, some material may be extruded from between the engaged surfaces452,418. For example, inFIG.6G, the extruded material is shown located in the unfilled part “J1”. For convenience, the extruded material is identified inFIG.6Gby reference characters “K1”, “K2”. It will be understood that the extruded material may be extruded at any point(s) where the first insert engagement surface(s)452and the opening wall surface(s)418meet. It is believed that the extruded material will tend to be extruded into a nearby void, e.g., the parts “J1”, “J2”.

Preferably, in order to complete the repair or replacement of the preselected region411of the original workpiece410, the unfilled parts “J1”, “J2” of the initial opening412are to be filled, as will be described.

In order to achieve this, one or more border regions or peripheral regions457are removed from the body481at least partially around the one or more unfilled parts “J1”, “J2” to form one or more corresponding supplementary opening walls464in the body481, producing a residual segment469of the body481(FIGS.6G,6H). Each of the supplementary opening walls464has one or more supplementary opening wall surfaces466defining a supplementary opening462(FIGS.6D,6H). Each of the supplementary openings462encompasses, or coincides with or includes, one of the unfilled parts “J”, “J”. The unfilled parts are outlined in dashed lines inFIG.6H.

In the example illustrated inFIG.6H, there are two supplementary openings462, i.e., each one encompassing or including one of the parts “J1”, “J2” of the initial opening412. Those skilled in the art would appreciate that the supplementary openings462may be formed using any suitable tools.

InFIGS.6D and6G, a dashed line464′ indicates the location of the supplementary opening wall464in relation to the unfilled part “J1”. As can be seen inFIGS.6G and6H, the peripheral regions457are located around, or partially around, the unfilled parts “J1”, “J2” that are formed when the insert458is fused or bonded with the remainder segment456. In the examples illustrated inFIGS.6G and6H, the peripheral regions457are removed from the body481in order to provide the supplementary openings462that are round, in plan view. As will be described, this shape of the supplementary opening may facilitate an engagement motion of the plug, thereby facilitating bonding or fusing plugs with the residual segment469.

It is also preferred that one or more plugs468are provided that are metallically bondable with the residual segment469(FIGS.6I,6J). Each plug468preferably is formed to at least partially fit into one of the supplementary openings462. As will be described, the plug468preferably includes one or more plug engagement surfaces470(FIG.6I) that are formed for engagement with the supplementary opening wall surface(s)466.

Preferably, one or more heating elements426′,424′ are positioned in preselected positions relative to the plug engagement surface470and to the supplementary opening wall surface466respectively (FIG.6I). Also, an inert (non-oxidizing) atmosphere preferably is provided, covering the plugs468, the heating elements, and the residual segment469. A cover or container for containing the non-oxidizing atmosphere is omitted from the drawings for clarity of illustration.

For clarity, the two supplementary openings are identified inFIG.6Hby reference characters462A,462B. In the following description, only one plug468and only one of the supplementary openings462are described, for clarity. Those skilled in the art would appreciate that the processes for securing plugs458in each of the supplementary openings462are the same in all relevant respects.

As can be seen inFIG.6I, in one embodiment, one or more first heating elements424′ preferably are positioned proximal to the supplementary opening wall surface466(FIG.6I). Also, one or more second heating elements426′ preferably are positioned proximal to the plug engagement surface470(FIG.6I).

Next, the heating elements424′,426′ are energized, in the non-oxidizing atmosphere.

With the first heating elements424′, in the non-oxidizing atmosphere, one or more residual segment heated portions465′ are heated to the hot working temperature. Each of the residual segment heated portions465′ extends from the supplementary opening wall surface466into the residual segment469. It will be understood that the residual segment heated portion465′ is plastically deformable at the hot working temperature.

With the second energized heating elements426′, in the non-oxidizing atmosphere, heating a plug heated portion467′ is heated to the hot working temperature. The plug heated portion467′ extends from the plug engagement surface470into the plug468. It will also be understood that the plug heated portion467′ is plastically deformable at the hot working temperature.

Once the residual segment heated portion465′ and the plug heated portion467′ are at the hot working temperature, the heating elements424′,426′ preferably are removed, to enable the plug468to be moved to engage the residual segment469(FIGS.6I,6J).

While the residual segment heated portion465′ and the plug heated portion467′ are at the hot working temperature, the plug468preferably is subjected to a secondary engagement motion, to move the plug engagement surface470relative to the supplementary opening wall surface466.

The plug's secondary engagement motion may be any suitable motion thereof, relative to the residual segment469. For example, the plug468may be rotated or oscillated about its axis “4X”. Alternatively, the plug468may be oscillated in an axial direction.

While the plug468is subjected to the secondary engagement motion, and while the residual segment heated portion465′ and the plug heated portion467′ are at the hot working temperature, the plug468is additionally subjected to a plug translocation motion to push the plug468at least partially into the supplementary opening462. The direction of the translocation motion is indicated by arrow “4D1” inFIG.6I.

While the plug468is subject to the secondary engagement motion, and while the residual segment heated portion465′ and the plug heated portion467′ are at the hot working temperature, the plug engagement surface470is pressed against the supplementary opening wall surface466, to cause plastic deformation of the residual segment heated portion465′ and of the plug heated portion467′, for creating a metallic bond between the plug468and the residual segment469.

The direction in which pressure is exerted upon the plug468, in order to press the plug engagement surface470against the supplementary opening wall surface466is indicated by arrow “4G1” inFIG.6J.

Subsequently, the plug and the residual segment are allowed to cool, to bond the plug468and the residual segment469together.

As can be seen inFIG.6H, in one embodiment, the supplementary opening462preferably is round.

Preferably, the plug468is a right circular cone. Alternatively, the plug468may be frustoconical.

In the embodiment of the method of the invention illustrated inFIGS.6A-6J, once bonded therein, the first insert458substantially occupies the initial opening412in the workpiece410. However, those skilled in the art would appreciate that, where the initial opening412is relatively long, maintaining a suitable engagement motion of the insert458may not be practical, e.g., due to the length of the initial opening412. For example, a large pipe made of relatively thick rolled metal (e.g., such as the prior art example illustrated inFIG.1A) may be several feet long, with a correspondingly long opening therein, along all or part of its length. Also, where the opening to be filled is not generally straight (i.e., non-linear), it may not be feasible to utilize a single insert to occupy most of the opening. An embodiment of the method of the invention intended to address these situations is illustrated inFIGS.7A-7F.

It will be understood that the embodiment of the method of the invention illustrated inFIGS.7A-7Fmay be utilized to complete or finish a workpiece, or to repair a damaged or worn workpiece.

A partially-modified or incomplete workpiece560is illustrated inFIG.7A. A body portion581of the workpiece is shown, the body portion being the portion of the workpiece that defines an initial opening in the body portion581.

First inserts558,559are secured to the body portion581(FIG.7A). As illustrated inFIG.7A, the initial opening in the incomplete workpiece560is partially occupied by left and right first inserts558,559(as shown inFIG.7A), which are spaced apart from each other by an unfilled part “L1” of the original (initial) opening. The incomplete workpiece560includes the body portion581, and the left and right first inserts558,559. The left and right first inserts558,559also define unfilled parts “L2”, “L3” at their respective ends. The unfilled parts “L1”, “L2”, and “L3” are parts of the initial or original opening in the workpiece that remain unoccupied after the left and right first inserts558,559are bonded to the body portion581(FIGS.7A-7C).

It will be understood that the left and right first inserts558,559preferably are bonded with the body portion581using any suitable embodiment of the method of the invention described above, e.g., such as the method used in connection with bonding the first insert458to the remaining portion456(FIGS.6C-6E). Those skilled in the art would appreciate that the left and right first inserts558,559are not required to be bonded simultaneously with the body portion581. It is expected that, due to space constraints, bonding one of the first inserts with the body portion581, and then subsequently bonding the other first insert with the body portion581, is likely to be preferred in practice.

Because the method of bonding the first inserts558,559with the body portion581is described above, further description thereof is unnecessary. The heating elements and other elements needed for bonding the left and right first inserts558,559with the body portion581are omitted fromFIGS.7A-7Cfor clarity of illustration. It will be understood that some extruded material (not shown) may be extruded into the unfilled parts “L1”-“L3”.

It will also be understood that only two first inserts558,559are illustrated in order to simplify the illustration. However, those skilled in the art would appreciate that there may be any suitable number of first inserts, with a corresponding number of unfilled parts of the initial opening therebetween, depending on (among other things) the overall length of the initial opening that is to be partially filled, and the shape thereof.

In order to fill the unfilled parts “L1”-“L3” of the initial opening, supplementary openings561,562, and563preferably are formed in the incomplete workpiece560(FIG.7D). Dashed lines inFIG.7Dshow the locations of the supplementary openings. The locations of the respective supplementary openings561,562,563are shown inFIG.7D. The supplementary openings561,562,563may be formed in any suitable manner, and may involve removal of material from the workpiece560. In one embodiment, the method preferably includes removing one or more peripheral regions557from the body portion581to form one or more supplementary opening walls having one or more supplementary opening wall surfaces566thereon defining the one or more supplementary openings561,562,563, producing a residual segment569of the body581(FIG.7F). The supplementary openings561,562,563are in the residual segment569.

In the examples illustrated inFIG.7D, the peripheral regions557are removed from the partially-modified workpiece560in order to provide respective supplementary openings that are round, in plan view. As will be described, this shape of the supplementary opening may facilitate an engagement motion of each plug to be inserted therein, thereby facilitating bonding or fusing plugs with the residual segment569.

As can be seen inFIG.7D, for instance, the supplementary opening561, once formed, encompasses the unfilled part “L2”. The other supplementary openings562,563preferably encompass or include or incorporate the unfilled parts “L1” and “L3” respectively.

Plugs568preferably are provided that are bondable or fusible with the metal of the body portion581, and with the metal of the left and right first inserts558,559(as illustrated inFIG.7D). The plugs568preferably are formed to fit into each of the supplementary openings561,562,563respectively. For clarity of illustration, inFIG.7F, the plugs that are shown located in the supplementary openings561,562,563are identified by reference characters568A,568B, and568C respectively.

One of the plugs568is shown positioned in one of the supplementary openings inFIG.7E. Each of the supplementary openings561,562,563preferably is at least partially defined by the supplementary opening wall surface566therefor (FIG.7E). Also, each of the plugs568preferably is partially defined by one or more insert engagement surfaces570thereof (FIG.7E) that are formed for engagement with the supplementary opening wall surface566of the one of the supplementary openings561,562,563, in which the plug568is to be positioned. As an example, one of the plugs568is shown in the supplementary opening561(FIG.7E).

It will also be understood that certain of the heating elements (not shown) are positioned proximal to the respective plugs, and energized to heat the respective plug heated portions. The non-oxidizing atmosphere covers the heating elements, the plug, and the residual segment. The heating elements and a cover or container for containing the non-oxidizing atmosphere are omitted from the drawings for clarity of illustration.

Preferably, residual segment heated portions565are heated by heating elements (not shown), in a non-oxidizing atmosphere, to the hot working temperature, in the same manner as described above. It will be understood that certain of the heating elements (not shown) are positioned in the respective supplementary openings, and energized to heat the respective residual segment heated portions. Also, plug heated portions567are heated to the hot working temperature by the heating elements, in the non-oxidizing atmosphere.

Each of the residual segment heated portions565preferably extends from the supplementary opening wall surface566into the residual segment569. Similarly, each of the plug heated portions567preferably extends from the plug engagement surface570into the plug568.

For clarity of illustration, only the residual segment heated portion565that is proximal to the supplementary opening561and the plug heated portion567in the plug568located in that supplementary opening are shown inFIG.7E.

In order to simplify the description, only one plug and one supplementary opening is described. It will be understood that the plugs are the same, and the supplementary openings and the supplementary opening walls are the same, in all relevant respects.

When the modified workpiece heated portion565and the plug heated portion567are heated to the hot working temperature, each of them is plastically deformable.

Preferably, the plug568is subjected to a second engagement motion, to move the plug engagement surface570relative to the supplementary opening wall surface566. While the plug568is subjected to the second engagement motion, and while the plug engagement surface570and the supplementary opening wall surface566are at the hot working temperature, the plug568preferably is also additionally subjected to a second translocation motion, to move the plug568at least partially into the supplementary opening therefor, for engaging the plug engagement surface570with the supplementary opening wall surface566thereof.

Once the plug engagement surface570engages the supplementary opening wall surface566, the second engagement motion preferably continues, until the plug568and the residual segment569are bonded or fused together.

Preferably, the plug engagement surface570is pressed against the supplementary opening wall surface566, while the second engagement motion continues, and also while the residual segment heated portion565and the plug heated portion567are at the hot working temperature, to cause plastic deformation of the residual segment heated portion565and of the plug heated portion567as they engage each other, for creating a metallic bond between the plug568and the residual segment569.

InFIG.7E, for example, one of the plugs568is shown located in one of the supplementary openings561and bonded with the residual segment569. It will be understood that the plug568is pressed in the direction indicated by arrow “5G” inFIG.5E, to press the plug engagement surface570against the supplementary wall opening surface566while the plug568is subjected to the second engagement motion.

It is also preferred that the plugs568and the residual segment569are subsequently allowed to cool, to form a modified workpiece572(FIG.7F) that includes the plugs568(i.e., one plug568being located in each of the supplementary openings561,562,563respectively) and the residual segment569.

In the example illustrated inFIG.7F, there are three supplementary openings561,562, and563, and three plugs568are bonded or fused to the residual segment569in the three supplementary openings561,562, and563respectively. Accordingly, once the plugs568are in the supplementary openings561,562, and563, the workpiece is completed, and may be utilized.

The plug568may be a right circular cone. In one embodiment, the plug568is frustoconical (FIG.7E). The engagement motion may be a rotational or oscillating motion of the plug568, about its axis “5X”. Alternatively, the plug may be axially oscillated. As noted above, each supplementary opening preferably is round in plan view.

It will be understood that the number, size and shape of the supplementary openings may be any suitable number, size and shape, as required in order to fill the unfilled parts (e.g., “L1”, “L2”, “L3”) of the initial opening. The inserts558,559and the plug568may have any suitable configurations also. The process may involve any suitable number of first inserts, and therefore also may involve any suitable number of supplementary openings and plugs.

Those skilled in the art would appreciate that the embodiment of the method illustrated inFIGS.7A-7Fmay also be utilized to fill unfilled parts of initial openings in the workpiece that are not elongate and straight. For example, such embodiment may be utilized to fill an elongate opening that is not linear (i.e., straight) along its length, but is instead non-linear. This may be accomplished by dividing the elongate non-linear opening into a series of smaller linear segments, each linear segment being filled by one or more first inserts and one or more plugs, as described above.

From the foregoing, it can be seen that the embodiment of the method of the invention illustrated inFIGS.7A-7Fresults in the completed or repaired workpiece572(FIG.7F), in which the replacement of the damaged region has been effected without creating heat-affected zones in the completed workpiece572.

It will also be understood that the translocation motion of the first inserts and the plugs may, alternatively, be directed radially outwardly from the interior of the pipe or tube workpiece toward its exterior, where the relevant elements are formed to accommodate this.

Those skilled in the art would appreciate that such method (and other embodiments of the method of the invention described herein) may be utilized in situ, e.g., where the workpiece cannot be moved, or at least cannot conveniently be moved.

As can be seen, e.g., inFIG.8A, it may be desirable to bond a number of plates together. In the example illustrated inFIGS.8A-8J, three plates675,676,677are bonded or fused together. It will be understood that the plates may be flat, concave, convex, or combinations thereof. The plates675,676,677may be secured together, for instance, to form a structure, or to form part of a structure.

In one embodiment, the method of the invention is for securing a number of the plates together to form a structure672(FIG.8H). The method preferably includes, first, securing two or more of the plates675,676,677to produce an intermediate segment656of the structure672having an initial opening612therein (FIG.8B). As an example, inFIGS.8A and8B, the plates675,676are shown secured along their respective adjacent edges671A,671B. Also, the plates675,677are shown as being secured to each other along respective adjacent edges673A,673B. As can be seen inFIG.8B, in this example, the three plates675,676,677form the intermediate segment656of the structure, which defines the initial opening612therein between the plates676,677.

The opening612is formed because, once the plates675,676,677have been secured together, two of the three plates (i.e., the plates676,677, in the example illustrated inFIG.8B) are not thereafter movable relative to each other, to close the initial opening612. Preferably, the plates675,676,677are bonded or fused together utilizing techniques described above.

For example, it will be understood that the plates675,676may be bonded together by, first, heating heated portions thereof (not shown) that are adjacent to the edges671A,671B of the plates in a non-oxidizing atmosphere. The heated portions are heated by heating elements (not shown) to the hot working temperature. The heating may be, for example, by induction. Once the heated portions are at the hot working temperature, at which they are subject to plastic deformation, one or both of the plates675,676may be moved relative to the other, in an engagement motion. Arrows “6Y1”, “6Y2” schematically represent such motion (FIG.8A). While the heated portions are at the hot working temperature, and while one or both of the plates675,676are subjected to the engagement motion, the edges671A,671B are pushed together, as indicated by arrows “6D1” and “6D2” (FIG.8A), to bond the plates675,676together along their respective edges671A,671B. The engagement motion continues while the edges671A,671B are pressed together, until the plates675,676are bonded or fused together.

Similarly, in the example illustrated inFIG.8A, heated portions (not shown) of the plates675,677that are adjacent to the edges673A,673B of the plates675,677are heated in a non-oxidizing atmosphere to the hot working temperature by heating elements (not shown). One or both of the plates675,677are subjected to an engagement motion, schematically represented by arrows “6Y3”, “6Y4”. The edges673A,673B preferably are pushed together, as indicated by arrows “6D3”, “6D4”, to bond the plates675,677together along the edges673A,673B.

It will be understood that a number of elements utilized in connection with joining the plates together (e.g., heating elements, and a cover or container for containing the non-oxidizing atmosphere) are omitted from the drawings, for clarity of illustration.

Because embodiments of the method of the invention used in joining the plates675,676,677together to form the intermediate segment656are described above, further description thereof is unnecessary.

In the example illustrated inFIGS.8A and8B, the foregoing steps result in the plates675,676,677forming the intermediate segment656, having the initial opening612therein. Preferably, the intermediate segment656includes one or more opening walls616at least partially around the initial opening612(FIG.8B). The opening walls616have opening wall surfaces618thereof, defining the initial opening612(FIG.8D).

It is preferred that an insert658that is metallically bondable with the intermediate segment656is provided (FIG.8C). The insert658preferably is formed to at least partially fit into the initial opening612. In the example illustrated inFIGS.8B and8C, the initial opening612is elongate, and the insert658is also elongate, to fit therein. Preferably, the insert658has an insert engagement surface652formed for engagement with the opening wall surfaces618(FIG.8D).

As can be seen inFIG.8D, one or more heating elements624preferably are positioned in predetermined positions relative to the insert engagement surface652and to the opening wall surface618. It will be understood that certain elements are omitted from the drawings for clarity, and separate heating elements may be used to heat the insert658and the opening walls616respectively.

A non-oxidizing atmosphere preferably is provided that covers the heating elements and at least the portions of the insert658and the intermediate segment656that are to be heated. It will be understood that a cover or container for holding the non-oxidizing atmosphere in position is omitted from the drawings, for clarity of illustration.

Next, the heating elements are energized in the non-oxidizing atmosphere. With the one or more energized heating elements, an intermediate segment heated portion665is heated to the hot working temperature. The intermediate segment heated portion665is plastically deformable at the hot working temperature. As can be seen inFIG.8D, the intermediate segment heated portion665extends from the opening wall surfaces618into the intermediate segment656.

With the one or more energized heating elements, an insert heated portion667is heated to the hot working temperature, at which the insert heated portion667is plastically deformable. As can also be seen inFIG.8D, the insert heated portion667extends from the insert engagement surface652into the insert658.

Next, while the intermediate segment heated portion665and the insert heated portion667are at the hot working temperature, the insert658is subjected to an insert engagement motion, to move the insert engagement surface652relative to the opening wall surface618. The insert engagement motion may be any suitable motion. As can be seen inFIG.8C, in one embodiment, the insert658may be elongate, to fit into the opening612. In the example illustrated, the engagement motion may be an oscillation of the insert658, in the directions indicated by arrow “6Y5” (FIG.8C).

Preferably, while the insert658is subject to the engagement motion, and while the insert heated portion667and the intermediate segment heated portion665are at the hot working temperature, the insert658is subjected to a translocation motion to push the insert658at least partially into the opening612. The translocation motion of the insert658is indicated by arrow “6D5” inFIGS.8D and8E.

While the insert658is subject to the engagement motion, and while the insert heated portion667and the intermediate segment heated portion665are at the hot working temperature, the insert engagement surface652preferably is pressed against the opening wall surface618, to cause plastic deformation of the intermediate segment heated portion665and also of the insert heated portion667, for creating a metallic bond between the insert658and the intermediate segment656. The insert658is pressed in the direction indicated by arrow “6G” inFIG.8E. The insert658and the intermediate segment656are then allowed to cool, to bond the insert658and the intermediate segment656together.

As can be seen inFIG.8F, due to the oscillation of the insert658, when the insert658is fused or bonded with the intermediate segment660, the insert658does not fully occupy the opening612. InFIG.8F, the insert658is bonded with the intermediate segment656, and unfilled parts “6J1” and “6J2” of the initial opening612that are vacant or unfilled are defined at the respective ends of the insert658. The unfilled parts “6J1” and “6J2” remain open once the insert658is bonded or fused with the intermediate segment656. The intermediate segment656and the insert658, once bonded together, form a body681of an incomplete workpiece660. The incomplete workpiece660includes the body681and the unfilled parts “6J1”, “6J2” (FIG.8F).

In order to complete the incomplete workpiece660, the unfilled parts “6J1”, “6J2” of the initial opening612preferably are filled, as will be described. Preferably, additional material is removed from one or more peripheral regions657of the body681at least partially around the unfilled parts “6J1”, “6J2”, to form one or more supplementary opening walls664, producing a residual segment669of the body681. For clarity of illustration, the locations of the supplementary opening walls, identified by reference character664′, are shown inFIG.8Gin dashed lines.

The supplementary opening wall664has a supplementary opening wall surface666defining a supplementary opening662(FIG.8I). Each of the supplementary openings662preferably includes or encompasses or incorporates the one or more unfilled parts “6J1”, “6J2”.

In the example illustrated inFIG.8G, there are two supplementary openings662, each of which encompasses one of the parts “6J1”, “6J2” of the initial opening612respectively. Those skilled in the art would appreciate that the supplementary openings662may be formed using any suitable tools.

In one embodiment, each supplementary opening662preferably is defined by one or more supplementary opening walls664that are at least partially formed in the insert658. As can be seen inFIG.8G, one of the supplementary openings662, coinciding with the unfilled part “6J1”, is defined by an opening wall664that is partly formed in the insert658and also formed in each of the plates675,676, and677. The other supplementary opening662coincides with the unfilled part “6J2” (FIG.8G). Each of the supplementary opening walls664has one or more supplementary opening wall surfaces666(FIG.8I). As will be described, it is preferred that the supplementary openings662are round in plan view. Accordingly, to form the supplementary openings662, one or more peripheral regions657are removed from the body681of the incomplete workpiece660to produce the residual segment669(FIG.8G).

To simplify the description, only one plug and its movement into only one supplementary opening is described.

Preferably, the plug668is metallically bondable with the residual segment669. The plug668is formed to at least partially fit into the supplementary opening662. The plug has a plug engagement surface670formed for engagement with the supplementary opening wall surface666.

As can be seen inFIG.8I, one or more heating elements624preferably are positioned in a preselected position relative to the plug engagement surface670and to the supplementary opening wall surface666. As described above, a non-oxidizing atmosphere is provided, covering the plug, the heating elements, and the residual segment669. Next, the one or more heating elements624are energized.

With the one or more energized heating elements624, the residual segment heated portion678is heated in the non-oxidizing atmosphere to a hot working temperature, at which the residual segment heated portion678is plastically deformable. The residual segment heated portion678extends from the supplementary opening wall surface666into the residual segment669.

With the one or more energized heating elements624, a plug heated portion679is heated in the non-oxidizing atmosphere to the hot working temperature, at which the plug heated portion670is plastically deformable. The plug heated portion679extends from the plug engagement surface670into the plug668.

Next, while the residual segment heated portion678and the plug heated portion679are at the hot working temperature, the plug668preferably is subjected to a secondary engagement motion, to move the plug engagement surface670relative to the supplementary opening wall surface666.

While the plug668is subjected to the secondary engagement motion, and while the residual segment heated portion678and the plug heated portion679are at the hot working temperature, the plug668is additionally subjected to a plug translocation motion to push the plug668at least partially into the supplementary opening662, in the direction indicated by arrow “6D6” inFIG.8I.

While the plug668is subject to the secondary engagement motion, and while the residual segment heated portion678and the plug heated portion679are at the hot working temperature, the plug engagement surface670is pressed against the supplementary opening wall surface666, to cause plastic deformation of the residual segment heated portion678and the plug heated portion679for creating a metallic bond between the plug668and the residual segment669. The direction in which the plug668is pressed is indicated by arrow “6G1” inFIG.9J.

The plug668and the residual segment669are allowed to cool, to bond the plug668and the residual segment669together.

It will be understood that the secondary engagement motion may be, for example, rotation of the plug668about its axis “6X”, or oscillation about the axis (FIG.8I). Preferably, the secondary engagement motion is an oscillation. The secondary engagement motion may involve motion in the axial direction.

Another situation in which relatively large objects may be secured together by utilizing the method of the invention is illustrated inFIGS.9A-9E. An incomplete workpiece760is illustrated inFIGS.9A and9B. The incomplete workpiece760includes a body781that includes two tubes701A,701B (FIG.9A) that are connected by first inserts702A,702B,702C, and702D (FIGS.9A,9B).

It will be understood that the first inserts702A,702B,702C, and702D may be bonded to the respective tubes701A,701B using embodiments of the method of the invention described above. As can be seen inFIGS.9A and9B, the first inserts702A,702B,702C, and702D define respective initial openings712A,712B,712C, and712D therebetween. Because embodiments of the method of the invention used in joining the first inserts702A-702D to the tubes701A,701B are described above, further description thereof is unnecessary.

As can be seen inFIG.9C, it is preferred that second inserts are positioned in all four of the initial openings, to partially fill the respective initial openings. Only two of the second inserts,758A,758B, are shown inFIG.9C, for clarity of illustration. It can be seen inFIG.9Cthat the second inserts758A,758B partially fill the initial openings712A,712B respectively.

It will also be understood that the second insert758A preferably is bonded or fused with the first inserts702A,702B, and the second insert758B preferably is bonded to the first inserts702B,702C, by utilizing embodiments of the invention described above. Because embodiments of the method of the invention used in bonding the second inserts to the first inserts are described above, further description thereof is unnecessary.

As can be seen inFIG.9C, the body781of the incomplete workpiece760and the second inserts define holes therein, i.e., unfilled parts of the initial openings712A-712D. It will be understood that only the holes or unfilled parts “7J1”-“7J4” are illustrated, for clarity of illustration (FIG.9C).

Next, supplementary opening walls764are formed (FIG.9F), to define supplementary openings762that encompass or coincide with the holes. The supplementary opening walls764preferably are formed by removing peripheral regions757from the body781. As examples, the locations of the supplementary opening walls formed around the holes “7J”-“7J” are shown in dashed lines inFIG.9D, identified by reference character764′.

In the following description, the utilization of an embodiment of the invention to fill only one of the unfilled parts is described. For the purposes of discussion, the description is related to filling the unfilled part identified by reference character “7J1”. It will be understood that the steps taken to fill the unfilled part “7J1” are the same as the steps taken to fill each other unfilled part respectively.

In one embodiment, the method of completing the incomplete workpiece710includes removing the peripheral regions757from the body781to form one or more supplementary opening walls764at least partially around the unfilled part of the initial opening to produce a residual segment769of the body781(FIG.9F). The supplementary opening wall764includes one or more supplementary opening wall surfaces766thereof defining one or more supplementary openings762in the residual segment769(FIG.9F). As an example, the supplementary opening762illustrated inFIG.9Fcoincides with or includes the hole “7J1”.

A plug768bondable with the residual segment769is provided. The plug768is formed to at least partially fit into the supplementary opening762. The plug768has a plug engagement surface770formed for engagement with the supplementary opening wall surface766.

Preferably, one or more heating elements724is positioned in a preselected position relative to the plug engagement surface770and the supplementary opening wall surface766(FIG.9F). A non-oxidizing (inert) atmosphere is provided that covers the plug, heating element, and the residual segment769. It will be understood that a cover or container for holding the non-oxidizing atmosphere in place is omitted from the drawings, for clarity of illustration.

Next, the heating element724is energized. With the energized heating element, a residual segment heated portion778is heated to a hot working temperature, at which the residual segment heated portion778is plastically deformable. The residual segment heated portion778extends from the supplementary opening wall surface766into the residual segment769.

With the energized heating element724, a plug heated portion779is heated to the hot working temperature, at which the plug heated portion779is plastically deformable. The plug heated portion779extends from the plug engagement surface770into the plug768. While the residual segment heated portion778and the plug heated portion779are at the hot working temperature, the plug768is subjected to an engagement motion, to move the plug engagement surface770relative to the supplementary opening wall surface766.

The engagement motion may, for example, be rotation or oscillation of the plug768about its axis “7X” (FIG.9F).

Next, while the plug768is subjected to the engagement motion, and while the residual segment heated portion778and the plug heated portion779are at the hot working temperature, additionally subjecting the plug768to a plug translocation motion, to push the plug768at least partially into the supplementary opening762. The direction of the translocation motion is indicated by arrow “7D” inFIG.9F.

While the plug768is subjected to the engagement motion, and while the residual segment heated portion778and the plug heated portion779are at the hot working temperature, the plug engagement surface770is pressed against the supplementary opening wall surface766, to cause plastic deformation of the residual segment heated portion778and the plug heated portion779for creating a metallic bond between the plug768and the residual segment769. The direction in which the plug768is pressed is indicated by arrow “7G” inFIG.9G. Finally, the plug768and the residual segment769are allowed to cool, to bond the plug768and the residual segment769together. Preferably, all the holes in the body781are filled in the same way, to produce a completed workpiece or structure772(FIG.9E).

It will be appreciated by those skilled in the art that the invention can take many forms, and that such forms are within the scope of the invention as claimed. The scope of the claims should not be limited by the preferred embodiments set forth in the examples, but should be given the broadest interpretation consistent with the description as a whole.