Patent ID: 7138598

Claim:
A method of joining a pair of overlapping workpieces, the method comprising: placing a first workpiece in overlapping relation to a second workpiece, the workpieces having surface characteristics that result in one or more gaps at an interface when the workpieces are placed one on top of the other, at least one of the one more gaps having a gap dimension equal to or greater than about 0.5 millimeters and equal to or less than about 2 millimeters; disposing a filler material at the interface between the pair of overlapping workpieces, the filler material comprising a skeletal structure having porous regions defined by solidly connected ligaments; applying a pressure to at least one of the workpieces so that the filler material is crushed to substantially fill the one or more gaps; and joining the two workpieces together in a region defined by the filler material.