Design and Manufacture of Pin Tools for Friction Stir Welding of Temperature-Resistant Materials

The primary goal of this SBIR Phase I project is to advance the development of low-cost, functionally graded laser additive manufactured high temperature refractory and cermet pin tools for friction stir welding (FSW) and/or friction stir processing (FSP) of heat-resistant materials. A solid state process, FSW produces high quality welds in difficult-to-weld materials and is fast becoming the process of choice for manufacturing lightweight transport structures including for space launch vehicles. Development of pin tools for FSW/FSP of the high temperature materials is a major challenge, as current pin tools are expensive and often fail prematurely. Production of pin tools using an Additive Manufacturing (AM) approach could offer a viable option for producing near-net shaped and relatively inexpensive functionally graded pin tools suitable for welding high temperature materials. The near-net-shape nature of this process not only minimizes the amount of machining and grinding involved, but also greatly reduces the time for manufacturing, or repair, of the pin tools.

Potential NASA Commercial Applications includes metal structures and components for space launch vehicles, spacecraft, airframes, and gas turbines, emphasizing high temperature applications.

Potential Non-NASA Commercial Applications includes metal structures and components for military and/or commercial space launch vehicles, spacecraft, airframes, air and land-based gas turbines, land vehicles (cars, trucks, trains), sea vehicles (recreation, passenger, cargo), and consumer products (electronics).

This is early/mid-stage (TRL 4) — the most realistic path in is NASA SBIR/STTR, which funds small businesses and research institutions to develop technology aligned with NASA's needs (equity-free, phased funding). Check whether a current SBIR/STTR solicitation topic overlaps with this project's technology area, or contact the project directly (above) to ask.

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