A method of joining conductors by friction stir welding.

Abstract

This disclosure relates in general to power cables. In particular, this disclosure relates to the joining and repair of conductors in power cables. [Solution] A method for joining a first conductor (1) of a power cable to a substantially cylindrical metal element (7), comprising: a) positioning the end of the first conductor (1) and a portion of the metal element (7) within a metal fixture (3); b) penetrating the metal fixture (3) with a rotary friction stir welding (FSW) tool (5); c) moving the rotary FSW tool (5) toward and through the contact surface (9) between the end of the first conductor (1) and the metal element (7) while penetrating the metal fixture (3) to join the end, the metal element (7), and the metal fixture; and d) removing excess metal fixture material from the joined end and the metal element (7) to obtain an FSW joint between the first conductor (1) and the metal element (7).

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