Patent ID: 6910616

Claim:
A method of constructing a preform for use in forming a machined structural assembly, comprising: determining the dimensions of the machined structural assembly; selecting first and second structural members bused on the dimensions of the machined structural assembly, the structural members including excess material such that at least one of the structural members is larger in at least one dimension than the corresponding dimension of the machined structural assembly; positioning the first structural member adjacent the second structural member so as to define at least two contact surfaces therebetween; and linear friction welding the at least two contact surfaces of die first and second structural members to construct the preform such that the preform defines an elongate friction weld joint and has dimensions approximating the dimensions of the machined structural assembly to thereby reduce material waste and machining time when forming the machined structural assembly, wherein said selecting step comprises selecting structural members with a combined mass of at least about twice the mass of the machined structural assembly.