Patent ID: 7270257

Claim:
A friction stir welding system that is capable of functionally friction stir welding high melting temperature ferrous and non-ferrous alloys, and superalloys, in a non-planar weld, said friction stir welding system comprising: a friction stir welding tool having a superabrasive material disposed on at least a portion of the shoulder and the pin, wherein the friction stir welding tool is disposed on a first side of a non-planar surface; and a support mandrel disposed against a second side of the non-planar surface so as to counteract a force applied by the friction stir welding tool to the first side, wherein the support mandrel is further comprised of: an inflatable bladder; a coiled sheet of material that can function as a surface of the support mandrel, wherein the inflatable bladder is disposed inside the coiled sheet, and wherein the inflatable bladder can inflate to uncoil the coiled sheet to thereby press against an inner surface of the non-planar surface.