Patent ID: 8506201

Claim:
A preform for forming a structural assembly having a predetermined configuration, the preform comprising: a base member; and a plurality of structural members, each structural member being connected by a linear friction weld joint to the base member, and each structural member defining a connection surface defining an angle relative to the base member, the connection surface of each structural member corresponding to and being in contact with the connection surface of an adjacent structural member and being connected by a friction weld joint to the connection surface of the adjacent structural member wherein the friction stir weld joint comprises an entry and an opposed exit displaced and positionally offset from an interface defined by the connection surfaces of the adjacent structural members, wherein each structural member is connected by one of the linear friction weld joints to a first surface of the base member and the connection surface of at least one structural member is disposed at an oblique angle relative to the first surface of the base member, wherein adjacent structural members and the associated linear friction weld joints are in continuous contact with the first surface of the base member from one of the adjacent structural members to another of the adjacent structural members across the corresponding connection surfaces, and wherein the structural members are configured to correspond to the predetermined configuration of the structural assembly.