Patent ID: 8061579

Claim:
A method of forming an enhanced structure from a fabrication preform having a first common surface and a recess below the first common surface, comprising: (a) disposing in at least a portion of the recess a filler selected from the group consisting of a metal/metal composite, a cermet composite, a bundle of wires, a bundle of rods, and a package of layered materials, wherein a first seam and a second seam are formed between the filler and at least a portion of the recess; (b) friction stir welding at least a portion of the first seam in a first pass performed at least in part along a first weld path to form a first bond; (c) friction stir welding at least a portion of the second seam in a second pass performed at least in part along a second weld path that is different from the first weld path to form a second bond; and (d) further stir mixing at least a portion of a material comprising one or more materials from which the first bond or the second bond are formed at least in part along a third path that is different from the first weld path and the second weld path.