Method for at least partially filling at least one opening in a metallic workpiece

Abstract

A method for at least partially filling an opening in a metallic workpiece, the opening being at least partially defined by one or more opening walls having one or more opening wall surfaces. The method includes providing an insert matable with the workpiece, the insert having one or more insert engagement surfaces formed to engage with the opening wall surfaces. The opening wall surfaces and the insert engagement surfaces are heated to a hot working temperature. The insert performs an engagement movement that moves the insert engagement surfaces relative to the opening wall surfaces. While the insert performs the engagement movement, the insert also performs a translation movement that moves the insert at least partially into the opening and engages the insert engagement surfaces with the opening wall surfaces to form at least a partial metallurgical bond between the insert and the workpiece.

Description

[Technical field]

[0001] The present invention relates to a method and system for modifying a metal object. [Background technology]

[0002] In the prior art, a conventional tube or pipe 10 may be formed to include a longitudinal opening 12 along its length (FIGS. 1A, 1B). The tube or pipe 10 may be formed by bending a relatively thick steel stock leaving an opening 12 along its length. Known methods for filling the opening typically result in a "heat affected zone" (not shown) along the edge of the longitudinal opening 12 (FIGS. 1A, 1B). As is known, the heat affected zone is an undesirable result as it is generally a weak portion of the tube.

[0003] FIG. 1C shows a partial cutaway view of a damaged tube or pipe 10' of the prior art. (As discussed below, embodiments of the invention are illustrated in the remaining accompanying drawings.) The tube or workpiece may be subject to various types of damage. In the illustrated example, a girth crack or opening "C1" (i.e., at least partially radial) and an elongated generally axial crack or opening "C2" (i.e., at least partially parallel to the longitudinal axis of the tube 10') have been formed in the tube 10'. However, known methods of filling these cracks or openings have the disadvantage of forming heat affected zones in the tube 10' that embrittle the tube 10'.

[0004] Solid state welding, in which one of two heated metal tubes is rotated so that the tubes engage and weld the tubes end-to-end, is disclosed in U.S. Pat. No. 5,399,343. Among its advantages, solid state welding can be performed without forming a heat-affected zone in the tubes joined using this technique. The tube ends form a metallurgical bond with a relatively uniform crystal structure. However, solid state welding requires the application of significant heat and force and has not been utilized to repair or otherwise modify metal workpieces having various shapes. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] U.S. Patent No. 6,637,642 Summary of the Invention [Problem to be solved by the invention]

[0006] For the foregoing reasons, there is a need for a method and system for modifying a metal object that overcomes or mitigates one or more deficiencies or drawbacks of the prior art. [Means for solving the problem]

[0007] In its broadest aspect, the invention provides a method for at least partially filling one or more apertures in a metallic workpiece, the apertures being at least partially defined by one or more aperture walls having one or more aperture wall surfaces. The method includes providing an insert capable of metallurgically bonding with the metal. The insert is formed to at least partially fit into the aperture. The insert has one or more insert engagement surfaces formed to engage with the aperture wall surface(s). The aperture wall surfaces are heated to a hot working temperature in a first non-oxidizing atmosphere. At the hot working temperature, the aperture wall surfaces are plastically deformable. The insert engagement surfaces are also heated to a hot working temperature in a second non-oxidizing atmosphere. At the hot working temperature, the insert engagement surfaces are plastically deformable. The insert performs an engagement motion that moves the insert engagement surfaces relative to the aperture wall surfaces. While the insert performs the engagement motion, and while the insert engagement surfaces and the aperture wall surfaces are at the hot working temperature, the insert also performs a translocation motion to move the insert at least partially into the aperture. During the engagement movement of the insert, the insert engagement surface engages the aperture wall surface causing plastic deformation of the aperture wall surface and the insert engagement surface as they engage one another to at least partially form a metallurgical bond between the insert and the workpiece, and the insert and workpiece are allowed to cool, causing the insert and workpiece to solidify together.

[0008] The invention may be better understood with reference to the accompanying drawings. [Brief description of the drawings]

[0009] [Figure 1A] FIG. 1 is an isometric view of a prior art metal tube having a longitudinal gap formed therein (as previously described). [Figure 1B] 1B (as explained above) is an enlarged cross-section of the tube of FIG. 1A. [Figure 1C]1 is a partial isometric view, drawn to scale, of another prior art metal tube including one or more openings or cracks formed therein (as previously described); FIG. [Figure 2A] 2 is an enlarged cross-sectional view of an embodiment of an insert and other elements of the present invention prior to moving the insert into an opening in a metal workpiece; FIG. [Figure 2B] 2B is a reduced cross-sectional view of the metallic workpiece of FIG. 2A with an insert disposed in an opening; [Figure 2C] 2C is an enlarged cross-sectional view of the metal workpiece of FIGS. 2A and 2B with an insert disposed in the opening; FIG. [Figure 2D] 10 depicts an enlarged cross-sectional view of another workpiece having an opening and an alternative embodiment of the insert of the present invention; [Figure 2E] 2D with the insert of FIG. 2D placed in the opening. FIG. [Figure 3A] 1 is a cross-sectional view of another embodiment of the insert of the present invention prior to moving the insert into an opening in a metal workpiece. [Figure 3B] 3B is a reduced cross-sectional view of the metallic workpiece of FIG. 3A with an insert disposed in an opening; [Figure 3C] 2 illustrates an enlarged cross-sectional view of another embodiment of a metallic workpiece and an insert of the present invention disposed in an opening in the metallic workpiece; [Figure 3D] 1 illustrates a reduced-scale partial isometric view of an embodiment of an insert disposed in an opening in a metallic workpiece; [Figure 3E] 1 is a partial cross-sectional view of a workpiece with an embodiment of an insert of the present invention disposed in an opening in the workpiece, the partial cross-sectional view being drawn to scale as the insert moves inward; [Figure 3F] 1 is a partial cross-sectional view of a workpiece having an embodiment of an insert of the present invention disposed in an opening in the workpiece and displacing the insert outward; [Figure 3G] 3B is an enlarged partial cross-sectional view of the workpiece and insert of FIG. 3A. [Figure 3H] 11 is a cross-sectional view of another workpiece having an opening and an alternative embodiment of the insert of the present invention. [Figure 3I] FIG. 3H is a cross-sectional view of the workpiece of FIG. 3H with the insert of FIG. 3H positioned in the opening. [Figure 4A] 1 is a reduced-scale top view of a workpiece in which an embodiment of a tube insert of the present invention is disposed; [Figure 4B] 4B is a cross-sectional view of the workpiece and tube insert of FIG. 4A, the cross-sectional view being depicted at a larger scale before the tube insert is moved toward the workpiece. [Figure 4C] FIG. 4C is a cross-sectional view of the workpiece and tube insert of FIGS. 4A and 4B, with the tube insert mated with the workpiece. [Figure 5A] FIG. 2 is a cross-sectional view of another embodiment of the insert of the present invention and a metallic workpiece prior to moving the tube insert towards the workpiece. [Figure 5B] FIG. 5B is a cross-sectional view of the metal workpiece of FIG. 5A with a tube insert mated therewith. [Figure 6A] 1 is a reduced plan view of a metallic workpiece having a defect area; [Figure 6B] FIG. 6B is a top view of the workpiece of FIG. 6A with the defect area removed to provide an opening. [Figure 6C] FIG. 6C is a top view of the workpiece of FIGS. 6A and 6B with a first insert disposed in the opening to provide a partially repaired workpiece. [Figure 6D] FIG. 6D is a cross-sectional view of the partially repaired workpiece of FIG. 6C. [Figure 6E] FIG. 6D is another cross-sectional view of the partially repaired workpiece of FIG. 6C. [Figure 6F]6D is an enlarged top view of a portion of the partially repaired workpiece of FIG. 6C. [Figure 6G] 6D is a reduced plan view of the partially repaired workpiece of FIG. 6C with auxiliary openings formed therein; FIG. [Figure 6H] FIG. 6H is a cross-sectional view of the workpiece of FIG. 6G with a second insert positioned in one of the auxiliary openings to mate with the partially repaired workpiece. [Figure 7A] 1 is a reduced plan view of another partially repaired workpiece; [Figure 7B] FIG. 7B is a cross-sectional view of the partially repaired workpiece of FIG. 7A. [Figure 7C] 7B is another cross-sectional view of the partially repaired workpiece of FIG. 7A. [Figure 7D] 7B is a reduced plan view of the partially repaired workpiece of FIG. 7A with auxiliary openings formed therein; FIG. [Figure 7E] FIG. 7E is a cross-sectional view of the workpiece of FIG. 7D with a second insert positioned in one of the auxiliary openings and mated with the partially repaired workpiece. [Figure 7F] FIG. 7B is a plan view of the repaired workpiece of FIGS. 7A-7E. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0010] In the accompanying drawings, like reference numerals indicate corresponding elements throughout, and in particular, for ease of illustration, the reference numerals used in Figures 1A-1C are used again in connection with the following description of the invention, but with each reference numeral increased by 100 (or an integer multiple thereof), and each element corresponds to an element shown in Figures 1A-1C.

[0011] 2A-3I, an embodiment of a method according to the present invention for at least partially filling one or more openings 112 in a metallic workpiece 110 will be described. For example, as can be seen in FIG. 3G, the opening 112 is at least partially defined by one or more opening walls 116 having one or more opening wall surfaces 118. In one embodiment, the method includes providing an insert 120, which preferably includes an insert material capable of metallurgically bonding to a metal. Those skilled in the art will also recognize materials that are capable of metallurgically bonding to each other.

[0012] As described below, the insert 120 is preferably formed to at least partially fit within the opening 112. The insert 120 preferably has one or more insert engagement surfaces 122 (FIG. 3G) formed to engage with the opening wall surface(s) 118.

[0013] Preferably, the aperture wall surface 118 is heated to a hot working temperature in a first non-oxidizing atmosphere. As will also be described below, once the aperture wall surface 118 is heated to the hot working temperature, the aperture wall surface 118 becomes plastically deformable. Also, preferably, the insert engaging surface 122 is heated to a hot working temperature in a second non-oxidizing atmosphere. Once the insert engaging surface 122 is also heated to the hot working temperature, the insert engaging surface 122 also becomes plastically deformable.

[0014] The hot working temperature is below the melting temperature of the metal. For purposes of this specification, "hot working temperature" may actually be a range of temperatures. One of ordinary skill in the art would know the appropriate hot working temperature and non-oxidizing atmosphere for a particular metal.

[0015] Preferably, the insert 120 undergoes an engagement motion to move the insert engagement surface(s) 122 relative to the opening wall surface(s) 118. As described below, the engagement motion may be an oscillating motion or a vibrating motion. While the insert 120 undergoes the engagement motion, and while the insert engagement surface 122 and the opening wall surface 118 are at the hot working temperature, the insert 120 also preferably undergoes a translation motion to move the insert 120 at least partially into the opening 112 to engage the insert engagement surface(s) 122 with the opening wall surface(s) 118.

[0016] As also described below, the insert 120 preferably undergoes both an engaging and a moving motion simultaneously to engage the moving insert engagement surface(s) 122 with the opening wall surface(s) 118 and induce plastic deformation as the opening wall surface(s) 118 and the insert engagement surface(s) 122 engage with one another to form at least a partial metallurgical bond between the insert 120 and the workpiece 110. Finally, the insert 120 and the workpiece 110 are cooled to solidify the insert 120 and the workpiece 110 together.

[0017] Those skilled in the art will recognize that the opening wall surface(s) 118 and the insert engagement surface(s) 122 require proper preparation (e.g., cleaning) before they are heated and subsequently engaged, and will also recognize suitable surface treatment techniques.

[0018] In the example shown in FIG. 3G, the aperture 112 is at least partially defined by two aperture walls 118. The aperture walls 118 may be heated to a hot working temperature by any suitable means. For example, FIG. 2A shows two aperture face heating elements 124 disposed proximate to each of the two aperture walls 118. Additionally, FIG. 2A also shows two insert heating elements 126 for heating the insert engagement surfaces 122, respectively, to a hot working temperature.

[0019] Once the aperture wall heating element 124 has heated the aperture wall 118 to the hot working temperature, the aperture wall heating element 124 is removed as shown by arrows "A1, A2" (FIGS. 2A, 3A), and once the insert engagement surface 122 has been heated to the hot working temperature, the insert heating element 126 is removed as shown by arrows "B1, B2" (FIGS. 2A, 3A).

[0020] During the engagement motion (as indicated by arrow "Y" in FIG. 3D), the insert 120 moves (i.e., translocates) into the opening 118 as indicated by arrow "D" in FIGS. 3D and 3G. As discussed above, the hot working temperature is the temperature at which the insert engagement surface 122 and the opening wall surface 118 undergo plastic deformation. The insert 120 simultaneously moves into engagement with the workpiece 110 as it performs the engagement motion. Upon engagement, the insert engagement surface 122 engages the opening wall surface 118. Once the insert 120 engages the workpiece 110, it continues its engagement motion to plastically deform the insert engagement surface 122 and the opening wall surface 118. For a short period of time immediately following the initial engagement of the insert engagement surface 122 with the opening wall surface 118, the insert 120 continues to move (i.e., performs the engagement motion) relative to the workpiece 110. It will be appreciated that the engagement is performed with significant force to achieve a metallurgical bond.

[0021] The engagement of the insert mating surface 122 and the opening wall surface 118, both at hot working temperatures, results in a region of material at the insert mating surface 122 and the opening wall surface 118 where a metallurgical bond is formed between the insert 120 and the workpiece 110. Such bond is the result of the applied mating force and the simultaneous mating movement of the insert relative to the workpiece while the mating surfaces 118, 122 are at the hot working temperature.

[0022] By this method, the workpiece and the insert are fused together to form a product that does not have a heat affected zone. The method of the present invention clearly results in a metallurgical bond zone "Z" (FIGS. 3E, 3F) where the insert and the workpiece are fused together, where the metal has a uniform crystal microstructure. As disclosed, for example, in U.S. Pat. No. 6,637,642, the metal is heated to a temperature at which the metal is plastically deformable (hot working temperature). It is also believed that in order to obtain a uniform crystal microstructure in the bond zone, it is important not to melt the metal during the heating and engagement steps of the method.

[0023] The workpiece metal and the insert metal may be any suitable material that can be fused together by the method of the present invention, such as alloys or metallic elements in this case. For example, fused metals include steel, aluminum, titanium, zirconium, Inconel™, and Hastelloy™, among others. Due to the applied heat and shear / forging pressure, the material in the bonded area has a relatively strong and uniform crystalline microstructure. For example, when the insert and workpiece are steel, the steel in the bonded area is known to be of the bainitic type.

[0024] The insert heating element 126 and the aperture surface heating element 124 may be any suitable heating element capable of providing sufficient heat. Those skilled in the art will recognize suitable heating elements. The heating elements 124, 126 are preferably configured to substantially uniformly heat the aperture wall surface(s) 118 and the insert engagement surface(s) 122, respectively. For example, as can be seen in FIG. 2A, the heating elements 124, 126 are preferably removable so that the heated insert engagement surface(s) 122 can engage the heated aperture wall surface(s) 118 once the surfaces 118, 122 reach a hot working temperature. Preferably, removal of the heating elements and subsequent engagement of the insert and workpiece all occur over a relatively short period of time to minimize the extent of heat loss from the surfaces 118, 122 prior to engagement with one another.

[0025] The aperture wall surface 118 is preferably uniformly heated (or nearly uniformly heated) to the hot working temperature. To achieve this uniformity, the aperture wall 116 is also preferably uniformly heated to the hot working temperature up to a first distance 128 from the aperture wall surface 118 of the aperture wall 116 (FIG. 3G). One of ordinary skill in the art would be able to determine an appropriate first distance.

[0026] Preferably, the insert engaging surface 122 is also uniformly heated (or nearly uniformly heated) to the hot working temperature. To achieve this uniformity, the insert 120 is also preferably uniformly heated to the hot working temperature from the insert engaging surface 122 to a second distance 130 of the insert 120 (FIG. 3G). One of ordinary skill in the art would be able to determine an appropriate second distance.

[0027] As previously discussed, the engagement motion of the insert 120 is intended to cause plastic deformation of each of the hot insert engagement surface 122 and the hot aperture wall surface 118 as the insert engagement surface 122 engages the aperture wall engagement surface 118 and continues thereafter. It is believed that the engagement motion and the force applied to engage the insert with the workpiece causes the materials of the insert engagement surface 122 and the aperture wall surface 118 to intermingle or mix to a very small extent. To that end, the engagement motion continues for a period of time after the surfaces 118, 122 engage one another. The engagement motion may be any suitable motion. For example, any repetitive motion of the insert 120 relative to the workpiece 110 may be suitable. For example, in one embodiment, the engagement motion is preferably a rocking motion relative to the workpiece 110.

[0028] As an example, as can be seen in FIG. 3D, the engagement motion of the insert may be longitudinal (i.e., back and forth) along the elongated opening 112 as the insert moves into the opening 112 with a translation motion. As mentioned above, the longitudinal engagement motion preferably continues for a short period of time after the insert first engages the opening wall, i.e., until the insert and the workpiece are coupled. Another example of an engagement motion is shown in FIG. 3G, where the insert 120 moves axially (i.e., back and forth in the direction of motion) as the insert 120 moves into the opening with a translation motion (indicated by arrow "D"). Again, the engagement motion preferably continues for a short period of time after the insert first engages the opening wall, i.e., until the insert and the workpiece are coupled.

[0029] Alternatively, in another embodiment, the rocking motion is preferably a linear motion of the insert, where the insert moves linearly relative to the workpiece, e.g., in any suitable direction. The rocking motion may instead move in any suitable pattern, e.g., in an arc or partial ellipse.

[0030] In another alternative embodiment, the engagement motion is preferably a rotation of the insert 120 relative to the workpiece 110, for example, about an axis "X" of the insert 120 (FIG. 3A). Alternatively, the engagement motion may be a vibration motion relative to the workpiece.

[0031] For example, as can be seen in Figure 3D, in one embodiment, the insert 120 preferably undergoes an engagement motion in which the insert 120 moves longitudinally along the opening 112, as indicated by arrow "Y" in Figure 3D. The arrow "Y" is double-headed to indicate a longitudinal rocking motion. In this example, the direction of the translation motion is perpendicular (or nearly perpendicular) to the back-and-forth direction of the engagement motion.

[0032] In one embodiment, the opening wall 118 is preferably planar and the insert engagement surface 122 is preferably planar as well (FIG. 3G). The opening wall engagement surface 118 and the insert engagement wall surface 122 are preferably formed to engage one another when the insert 120 is at least partially inserted into the opening 112. Preferably, the insert engagement surface 122 and the opening wall surface 118 are formed to cooperate with one another to at least partially position the insert 120 within the opening 112 such that respective regions of the surfaces are substantially engageable with one another.

[0033] As shown in Figures 2A, 3A, 3E, 3F and 3G, the translational movement is preferably in a predetermined linear direction into the opening 112. By way of example, the direction of the translational movement is indicated by an arrow "D" in Figures 2A, 3A, 3E, 3F and 3G. Preferably, the opening wall 118 is at a predetermined angle θ relative to the predetermined linear direction of the translational movement (Figure 3G). The predetermined angle may be any suitable angle. For example, in Figure 3G, the angle θ defined by the opening wall 118 relative to the direction of the translational movement of the insert is about 15°.

[0034] 2A-2C, one skilled in the art will appreciate that the aperture wall 118 is preferably substantially parallel to the insert engagement surface 122 which engages the aperture wall 118. In the embodiment shown in FIGS. 2A-2D, the insert 120 is preferably slightly wider than the aperture 112. That is, the width "W1" of the insert 120 shown in FIG. 2A is preferably slightly wider than the width "W2" of the aperture 112 when the surface is heated to a hot working temperature.

[0035] For example, as can be seen in FIG. 2B, in one embodiment, one or more clamps 132A, 132B preferably apply inward pressure (schematically represented by arrows “E1”, “E2”) to the workpiece 110 to maintain the shape of the workpiece 110 and hold the workpiece stationary.

[0036] As can be seen in Figures 2A, 2B, 3A, 3B, 3F and 3G, the translational motion is preferably in a predetermined linear direction into the opening 112. As shown in Figures 2B, 3B, 3F and 3G, the translational motion of the insert 120 may be, for example, inward (as indicated by arrow "D") or outward (as indicated by arrow "F").

[0037] When insert 120 is at least partially disposed within opening 112 and the insert is mated with a workpiece, one or more portions 134 thereof may extend beyond the opening wall(s) 118 of the workpiece to which insert 120 is mated (FIG. 2C). In this situation, portion 134 may be cut away or otherwise removed using any suitable means.

[0038] During engagement of the insert engagement surface 122 with the opening wall surface 118, small portions of the plastically deformed material may be extruded from the insert and / or workpiece along with exposed portions of the insert and / or workpiece at surfaces 118, 122. Depending on the specifications that the bonded or fused insert and workpiece must meet, it may be necessary to remove the extruded material once cooled, although in practice such removal may be difficult and time consuming.

[0039] Those skilled in the art will appreciate that the insert 120 may have any suitable configuration. In one embodiment shown in FIG. 3C, the insert 120 preferably extends between its inner end 136 and outer end 138, and the insert 120 also preferably includes one or more chamfered insert surfaces 140 located proximal to the insert engagement surface 122 at one or more of the inner end 136 and outer end 138. The chamfered insert surfaces 140 are preferably formed to minimize the amount of extrusion material that extends beyond the insert 120 and / or workpiece 110 on the inside and / or outside of the insert when the insert 120 and workpiece 110 are joined.

[0040] 3C, each of the aperture walls 118 preferably extends between an inner end 142 and an outer end 144. The workpiece 110 preferably includes one or more chamfered workpiece surfaces 146 located proximate the aperture wall(s) 118 at one or more of the inner end 142 and outer end 144. The chamfered workpiece surfaces 146 are preferably formed to minimize the amount of extruded material that extends beyond the insert 120 and / or workpiece 110 on the inside and / or outside of the insert.

[0041] The chamfered surfaces 140, 146 define a space into which the plastically deformed material squeezed out as the insert engages the workpiece can enter, preventing such material from being extruded into the interior of the tube workpiece or onto the exterior surface of the tube workpiece.

[0042] In one embodiment, the insert 120 preferably includes one or more notches 148 formed in the inner end 136 to minimize the amount of extrusion material that protrudes into the interior of the tube workpiece.

[0043] Workpiece 110 may include two or more layers of each metal. For example, as shown in Figures 2D and 3I, workpiece 110 may include a first layer 180 of a first metal and a second layer 182 of a second metal. To form workpiece 110, layers 180, 182 may be fused together using any suitable method.

[0044] When the workpiece 110 includes two or more layers of the respective metals, the insert 120 also preferably includes layers 184, 186 that are fused or bonded to layers 180, 182, respectively. When the insert 120 is at least partially placed in the opening, the layers 184, 186 can be metallurgically bonded to the layers 180, 182, respectively (FIGS. 2E, 3J). For example, as shown in FIGS. 2D and 2E and FIGS. 3I and 3J, in one embodiment, the insert 120 preferably includes layers 184, 186 that are steel and copper, respectively. The layers 184, 186 are also preferably formed such that when the insert 120 is at least partially placed in the opening 112, the layers 184, 186 are substantially aligned with the corresponding layers 180, 182 that are steel and copper, respectively, of the workpiece 110.

[0045] Heating elements 124', 126' are preferably used to heat the opening wall surface 118 and the insert engagement surface 122, respectively. Heating element 124' preferably includes first and second portions 189, 190 for heating first and second layers 180, 182, respectively. Heating element 126' also preferably includes first and second portions 191, 192 for heating layers 184, 186, respectively, of insert 120.

[0046] In another embodiment shown in Figures 4A-4C, the method of the present invention is for at least partially attaching a tube 250 to a metallic workpiece 210 to at least partially align the tube 250 with one or more openings 212 in the workpiece 210. The tube 250 is also made of a metal (i.e., preferably the same metal) capable of bonding with the metal of the workpiece 210. The openings 212 are at least partially defined by one or more opening walls 216 having one or more opening wall surfaces 218 (Figure 4B). The method preferably includes forming one or more tube engagement surfaces 252 on the tube 250 configured to engage the opening wall surface(s) 218. Preferably, the opening wall surface 218 is heated in a first non-oxidizing atmosphere to a hot working temperature at which the opening wall surface 218 is plastically deformable. Also, the tube engagement surface 252 is preferably heated in a second non-oxidizing atmosphere to a hot working temperature at which the tube engagement surface 252 is plastically deformable. The tube 250 then preferably undergoes an engagement movement to move the tube engagement surface 252 against the opening wall surface 218 .

[0047] For simplicity of illustration, the heating elements and clamps have been omitted from FIGS. 4A-5B. While the tube 250 is undergoing the engagement movement, and while the tube engagement surface 252 and the opening wall surface 218 are at the hot working temperature, the tube 250 also preferably undergoes a translation movement to move the tube 250 at least partially into the opening 250, whereby the tube engagement surface 252 engages the opening wall surface 218 during the tube engagement movement. This causes the opening wall surface 218 to plastically deform, and the tube engagement surface 252 to plastically deform as the opening wall surface 218 and the tube engagement surface 252 engage one another to form an at least partially metallurgical bond between the tube 250 and the workpiece 210, as described above. Finally, the tube 250 and the workpiece 210 are cooled to solidify the tube 250 and the workpiece 210 together.

[0048] As can be seen in Figures 4A-4C, the workpiece 210 may be, for example, a flat sheet of metal such as steel. Figure 4B shows the tube 250 and workpiece 210 just prior to engagement. Heating elements and other elements (e.g., clamps) necessary to carry out the method of the present invention have been omitted in Figure 4B for clarity of illustration.

[0049] The engagement motion may be, for example, a reciprocating or rocking rotational motion of tube 250 about axis "2X" of tube 250 as shown by arrows "2Y1" and "2Y2" in Figure 4A. The translation motion is in the direction shown by arrow "2D" in Figure 4B. The translation motion is preferably coaxial with axis "2X".

[0050] 4B, in one embodiment, tube engaging surface 252 is preferably planar and disposed at a selected angle relative to the direction of translational motion, and opening wall surface 218 is also preferably planar and disposed at a selected angle relative to the direction of translational motion.

[0051] As described above, while performing the engagement motion, the tube 250 simultaneously moves in the direction indicated by arrow "2D" to engage the tube engagement surface 252 with the opening wall surface 218. Preferably, after the tube engagement surface 252 initially engages the opening wall surface 218, the tube 250 still moves in accordance with the engagement motion. At that point in the method, the tube 250 continues to be pressed against the workpiece 210 in the direction indicated by arrow "2D" while performing the engagement motion. This causes the tube engagement surface 252 and opening wall surface 218 to plastically deform, fusing the tube 250 with the workpiece 210, as described above.

[0052] The tube 250 and workpiece 210 cool rapidly after initial engagement, causing the tube 250 and workpiece 210 to bond quickly, so that the engagement motion stops shortly after initial engagement and prevents further engagement motion.

[0053] 5A and 5B show tube 350 being coupled with workpiece 310. Tube 350 defines its axis "3X". Tube 350 is aligned with opening 312. In FIG. 5A, tube engagement surface 352 and opening wall surface 318 can be seen prior to engagement. Heating elements and other elements (e.g., clamps) necessary to carry out the method of the present invention have been omitted from FIG. 5A for clarity. Tube 350 performs an engagement motion while both tube engagement surface 352 and opening wall surface 318 are heated to a hot working temperature in a non-oxidizing atmosphere. The engagement motion may be, for example, a swinging rotational motion about tube 350 axis "3X". Tube 350 is then moved in the direction of the movement motion (indicated by arrow "3D"), still performing the engagement motion.

[0054] Upon engagement, the tube engagement surface 352 and the opening wall surface 318 plastically deform to form a metallurgical bond between the tube 350 and the workpiece 310 . Workpiece 310 may be, for example, the body of a manifold and tube 350 may be one of multiple tubes (not shown) secured to the body to form the manifold.

[0055] In another alternative embodiment shown in Figures 6A-6H, a method of the present invention is for repairing a workpiece 410 including a defect region 411 (Figure 6A). Preferably, the method includes removing a portion 454 of the workpiece 410 including the defect region 411 to provide an opening 412 in a remaining portion 456 of the workpiece 410. The opening 412 is defined by one or more opening walls 416 having one or more opening walls 418 (Figures 6D, 6E) in the remaining portion 456 of the workpiece 410. In one embodiment, the opening wall 418 may be formed, in part, at an angle selected to engage a surface of a first insert 458.

[0056] Preferably, a first insert 458 is provided having a first insert material capable of metallurgically bonding with a metal of the workpiece 410. The first insert 458 is preferably configured to at least partially fit within at least a portion of the opening 412, as shown in FIG. 6C. The first insert 458 has one or more first insert engagement surfaces 452 configured to engage with the opening wall surface 418 (FIG. 6D). Preferably, the opening wall surface 418 is heated in a first non-oxidizing atmosphere to a hot working temperature at which the opening wall surface 418 is plastically deformable. Also, the first insert engagement surface 452 is preferably heated in a second non-oxidizing atmosphere to a hot working temperature at which the first insert engagement surface 452 is plastically deformable.

[0057] Defective area 511 is defective or damaged or has been altered in some way such that the defective area must be replaced. For example, the defective area may be a portion of the workpiece that has corroded or weakened due to aging, or that contains pits or cracks caused by use. Alternatively, the defective area may include defects that were formed when the workpiece was manufactured.

[0058] It should be noted that for clarity, the heating elements and clamps, as well as other elements required for the method, have been omitted from FIGS. 6A-6H. The first insert 458 preferably undergoes a first engagement motion to move the first insert engagement surface 452 relative to the opening wall surface 418. While the first insert 458 is undergoing its first engagement motion, and while both the first insert engagement surface 452 and the opening wall surface 418 are at the hot working temperature, the first insert 458 also preferably undergoes a first translation motion to move the first insert 458 at least partially into the opening 412, and while the first insert 458 is undergoing its engagement motion, the first insert engagement surface 452 engages the opening wall surface 418 and plastically deforms as the opening wall surface 418 and first insert engagement surface 452 engage one another to at least partially form a metallurgical bond between the first insert 458 and the remainder 456 of the workpiece 410.

[0059] Figure 6D shows that the first insert 458 is positioned within the opening 412 and coupled with the remaining portion 456. The first translation motion is in the direction indicated by the arrow "4D1" in Figure 6D.

[0060] Finally, the first insert 458 and the remaining portion 456 of the workpiece 410 are cooled to provide a partially repaired workpiece 460 (Figure 6G) that includes the metallurgically bonded first insert 458 and the remaining portion of the workpiece 456 (Figures 6C-6F).

[0061] As can be seen in Figures 6C-6F, it is preferred that first insert 458 does not completely block opening 412. As shown in Figure 6C, partially repaired workpiece 460 includes openings "J1, J2," which are the portions of opening 412 that are not blocked after first insert 458 and remainder of the workpiece 456 are fused, i.e., metallurgically bonded, as described above.

[0062] As the first insert engagement surface 452 and the opening wall surface 418 engage and plastically deform, some material may be extruded from between the engagement surfaces 452, 418. For example, FIG. 6F shows the extruded material located at opening "J1". For convenience, the extruded material is identified by reference letters "K1, K2". The extruded material may be extruded at any point(s) where the first insert engagement surface(s) 452 and the opening wall surface(s) 418 meet. It is believed that the extruded material will tend to extrude into nearby voids, such as portions "J1", "J2", etc.

[0063] Preferably, portions "J1, J2" of opening 412 are filled as described below to complete the repair of damaged area 411 of the workpiece. However, in addition, extruded material "K1", "K2" is preferably removed to complete the repair of damaged area 411.

[0064] To accomplish this, one or more auxiliary openings 462 are preferably formed in the partially repaired workpiece 460 (FIG. 6G). As can be seen in FIG. 6G, in one embodiment, there are preferably two auxiliary openings 462, i.e., each auxiliary opening surrounding a portion "J1", "J2" of the initial opening 412. Each auxiliary opening 462 is preferably defined by one or more auxiliary opening walls 464 located at least partially in the first insert 458 and at least partially in what was the remaining portion 456 of the workpiece 410. The auxiliary opening walls 464 have one or more auxiliary opening wall surfaces 466 (FIG. 6H).

[0065] One or more second inserts 468 are also preferably provided that include a second insert material capable of metallurgically bonding with the metal of the workpiece and the first insert (FIG. 6H). The second inserts 468 are preferably formed to at least partially fit within the auxiliary openings 462. The second inserts 468 preferably include one or more second insert engagement surfaces 470(s) (FIG. 6H) that are formed to engage with the auxiliary opening wall surface(s) 466.

[0066] Preferably, the auxiliary opening wall 466 is heated in a non-oxidizing atmosphere to a hot working temperature at which the auxiliary opening wall 466 is plastically deformable. Similarly, the second insert mating surface 470 is preferably heated in a non-oxidizing atmosphere to a hot working temperature at which the second insert mating surface 470 is plastically deformable.

[0067] Preferably, the second insert 468 performs a second engagement movement to move the second insert engagement surface 470 relative to the auxiliary opening wall surface 466. While the second insert 468 is performing its second engagement movement, and while the second insert engagement surface 470 and the auxiliary opening wall surface 466 are at the hot working temperature, more preferably the second insert 468 also performs a second translation movement to move the second insert engagement surface 470 at least partially into the auxiliary opening intended to engage the auxiliary opening wall surface 466, causing plastic deformation as the auxiliary opening wall surface 466 and the second insert engagement surface 470 engage one another to cause an at least partial metallurgical bond between the second insert 468 and the partially repaired workpiece 460.

[0068] 6H shows one of the second inserts 468 being positioned in one of the auxiliary openings 462 and coupled with the partially repaired workpiece 460. The second translation motion is in the direction indicated in FIG. 6H by arrow "4D2."

[0069] It is also preferable to cool the second insert 468 and the partially repaired workpiece 460 to form a repaired workpiece 472 (FIG. 6H) including the second insert 468 and the partially repaired workpiece 460.

[0070] In the example shown in Figures 6G and 6H, there are two auxiliary openings 462 and two second inserts 468 are at least partially disposed in each of the two auxiliary openings 462. As can be seen in Figure 6H, the second inserts 468 preferably fill the auxiliary openings 462 and are metallurgically bonded to the partially repaired workpiece 460. Thus, once the second inserts 468 enter the auxiliary openings 462, the workpiece 410 is repaired and ready for use again.

[0071] From the foregoing, it can be seen that the embodiment of the method of the present invention illustrated in Figures 6A-6H results in a repaired workpiece 472 in which damaged area 411 has been replaced without creating a heat affected zone in repaired workpiece 472.

[0072] The number, size, and shape of the auxiliary openings 462 may be any suitable number, size, and shape. The first and second inserts 458, 468 may also have any suitable configuration.

[0073] For example, in one embodiment, the auxiliary opening 462 is preferably circular in plan view. Also, the second insert 468 is preferably a right circular cone. Preferably, the second insert 468 is a frusto-conical shape (FIG. 6H). The engagement motion may be a rotational motion of the second insert 468.

[0074] For clarity, the heating elements and clamps have been omitted from Figures 6A-6H. Additionally, the translational movement of the first and second inserts may alternatively be from the interior of the pipe or tube workpiece to its exterior if the associated elements are correspondingly configured.

[0075] Those skilled in the art will appreciate that such methods (as well as other embodiments of the inventive methods described herein) may be utilized, for example, in a field where the workpiece 410 cannot be moved, or at least cannot be conveniently moved.

[0076] In the embodiment of the method of the present invention shown in Figures 6A-6H, the first insert 458 substantially blocks the opening 412 of the workpiece 410. However, one skilled in the art will appreciate that when the opening 412 is relatively long, maintaining proper engagement motion of the first insert 458 may not be practical, i.e., due to the length of the first insert 458. For example, a large pipe made of relatively thick rolled metal (such as the prior art example shown in Figure 1A) may be several feet long and have a correspondingly long opening 12. Also, when the opening to be filled is generally not straight (i.e., non-linear), it may not be feasible to utilize a single first insert to block a majority of the opening. An embodiment of the method of the present invention intended to address these situations is disclosed in Figures 7A-7F.

[0077] The method embodiments of the present invention illustrated in Figures 7A-7F may be utilized to complete or finish a workpiece, or to repair a damaged or worn workpiece. A partially modified workpiece 560 is shown in Figure 7A. A body portion 556 of the workpiece is shown, which is the portion of the workpiece that defines the opening in the body portion 556.

[0078] As shown in FIG. 7A, the original opening of the workpiece 560 is partially blocked by left and right first inserts 558, 559 spaced apart from one another by an opening "L1". The partially modified workpiece 560 includes a body portion 556 and left and right first inserts 558, 559. The left and right first inserts 558, 559 also define openings "L2", "L3" at their respective ends. The openings "L1", "L2", and "L3" are the portions of the original opening of the workpiece that remain unblocked after the left and right first inserts 558, 559 are coupled to the body portion 556 (FIGS. 7A-7C).

[0079] The left and right first inserts 558, 559 are coupled to the body portion 556 using embodiments of the methods of the invention described above, such as the methods used in connection with coupling first insert 458 to remaining portion 456 (FIGS. 6C-6E). One skilled in the art will appreciate that the left and right first inserts 558, 559 do not have to be coupled to the body portion 556 at the same time. Due to space constraints, it may actually be preferable to couple one of the first inserts to the body portion 556 and then couple the other of the first inserts to the body portion 556.

[0080] Heating elements and other elements necessary to couple left and right first inserts 558, 559 to body portion 556 have been omitted from FIGS. 7A-7C for clarity. Some of the extruded material (not shown) may be extruded into the openings "L1"-"L3".

[0081] Also, for simplicity of illustration, only two first inserts are shown, although one skilled in the art will appreciate that there may be any suitable number of first inserts having a corresponding number of openings therebetween, depending (among other things) on the overall length of the openings to be filled.

[0082] Auxiliary openings 561, 562, 563 are preferably formed in the partially modified workpiece 560 to fill openings "L1"-"L3" and remove the extruded material therein (FIG. 7D). The auxiliary openings 561, 562, 563 may be formed in any suitable manner. As can be seen in FIG. 7D, auxiliary opening 561, when formed, preferably surrounds opening "L2". The other auxiliary openings 562, 563 preferably surround openings "L1" and "L3", respectively.

[0083] Preferably, second insert 568 comprises a second insert material capable of bonding with the metal of body portion 556 and the metal of left and right first inserts 558, 559. Second insert 568 is preferably formed to fit within each of auxiliary openings 561, 562, 563. For clarity, FIG. 7D shows one of second inserts 568 positioned within auxiliary opening 561.

[0084] Each of the auxiliary openings 561, 562, 563 is preferably at least partially defined by a auxiliary opening wall 566 (FIG. 7E). Each of the second inserts 568 is also preferably defined in part by one or more insert engagement surfaces 570 (FIG. 7E) formed to engage the auxiliary opening wall 566 of one of the auxiliary openings 561, 562, 563.

[0085] Preferably, each of the auxiliary opening walls 566 is heated in a non-oxidizing atmosphere to a hot working temperature at which the auxiliary opening walls 566 are plastically deformable. Similarly, the second insert mating surface 570 of each second insert 568 is preferably heated in a non-oxidizing atmosphere to a hot working temperature at which the second insert mating surface 570 is plastically deformable.

[0086] Preferably, the second insert 568 performs a second engagement movement to move the second insert engagement surface 570 relative to the auxiliary opening wall surface 566 with which the second insert 568 is positioned to engage. While the second insert 568 is performing its second engagement movement, and while the second insert engagement surface 570 and the auxiliary opening wall surface 566 are at the hot working temperature, more preferably the second insert 568 also performs a second translation movement to move the second insert engagement surface 570 at least partially into the auxiliary opening intended to engage the auxiliary opening wall surface 566, causing plastic deformation as the auxiliary opening wall surface 566 and the second insert engagement surface 570 engage one another to form an at least partially metallurgical bond between the second insert 568 and the partially repaired workpiece 560.

[0087] 7D and 7E show one of the second inserts 568 positioned in one of the auxiliary openings 561 and coupled with the partially modified workpiece 560. The second translation motion is in the direction indicated in FIG. 7E by arrow "5D2."

[0088] It is also preferable to cool the second inserts 568 and the partially modified workpiece 560 to form a modified workpiece 572 (Figure 7F) including the second inserts 568 (i.e., one second insert 568 is positioned in each of the auxiliary openings 561, 562, 563) and the partially modified workpiece 560.

[0089] In the example shown in Figures 7D, 7E and 7F, there are three auxiliary openings 561, 562, 563, and three second inserts 568 are at least partially disposed in the three auxiliary openings 561, 562, 563, respectively. As can be seen in Figure 7D, the second inserts 568 preferably fill the auxiliary openings 561 and are metallurgically bonded to the partially modified workpiece 560. Thus, once the second inserts 568 are in the auxiliary openings 561, 562, 563, the workpiece is modified and available for use.

[0090] In one embodiment, each auxiliary opening is preferably circular in plan view. Also, the second insert 568 is preferably a right circular cone. Preferably, the second insert 568 is a frustoconical shape (FIG. 7E). The engagement motion may be a rotational motion of the second insert 568.

[0091] The number, size and shape of the auxiliary openings may be any suitable number, size and shape. The first and second inserts 558, 559, 568 may also have any suitable configuration. The embodiment of the method shown in Figures 7A-7F is merely exemplary. The method may include any suitable number of first inserts, and therefore any suitable number of auxiliary openings and second inserts.

[0092] Those skilled in the art will appreciate that the method embodiments illustrated in Figures 7A-7F may also be utilized to fill openings in a workpiece that are neither elongated nor linear. For example, such embodiments may be utilized to fill an elongated opening that is not linear (i.e., straight) along the length of the elongated opening, but is instead non-linear. This may be accomplished by dividing the non-linear opening into a series of smaller linear portions, each of which is filled with one or more first inserts and one or more second inserts, as described above.

[0093] From the foregoing, it can be seen that the embodiment of the method of the present invention illustrated in Figures 7A-7F results in a modified workpiece 572 in which damaged area 411 has been replaced without creating a heat affected zone in modified workpiece 572.

[0094] Heating elements and other elements (eg, clamps) necessary to carry out the methods of the present invention have been omitted from FIGS. 7A-7F for clarity. Additionally, the translational movement of the first and second inserts may alternatively be from the interior of the pipe or tube workpiece to its exterior if the associated elements are correspondingly configured.

[0095] Those skilled in the art will appreciate that such methods (and other embodiments of the inventive methods described herein) can be utilized, for example, in on-site locations where the workpiece cannot be moved, or at least cannot be moved conveniently.

[0096] Those skilled in the art will appreciate that the present invention can take many forms, and that such forms are within the scope of the invention as claimed. The claims should not be limited by the preferred embodiments set forth in the examples, but should be accorded the broadest interpretation consistent with the description as a whole. The technical ideas that can be understood from the above-described embodiment will be described below as supplementary notes. [Appendix 1] 1. A system for at least partially filling at least one opening in a metallic workpiece, the at least one opening being at least partially defined by at least one opening wall having at least one opening wall surface, the system comprising: at least one clamping subassembly for holding the workpiece stationary; an insert including an insert material bondable with metal, the insert being configured to at least partially fit into at least one opening and having at least one insert engagement surface configured to engage with the at least one opening wall; at least one first heating element for heating the at least one aperture wall surface in a first non-oxidizing atmosphere to a hot working temperature at which the at least one aperture wall surface is plastically deformable; at least one second heating element for heating the at least one insert engaging surface in a second non-oxidizing atmosphere to a hot working temperature at which the at least one insert engaging surface is plastically deformable; and an insert movement subassembly for simultaneously causing an insert to undergo (i) an engagement movement in which the at least one insert engagement surface moves relative to the at least one aperture wall surface, and (ii) a movement movement in which the insert moves at least partially into the at least one aperture to plastically deform the at least one engagement surface and the at least one aperture wall surface as they engage with each other to effect a metallurgical bond between the insert and a workpiece; when the at least one aperture wall is heated to a hot working temperature from the at least one aperture wall surface to at least a first distance of the at least one aperture wall and the at least one insert engagement surface is heated to a hot working temperature from the at least one insert engagement surface to at least a second distance of the insert, the at least one first heating element and the at least one second heating element are removable; The system is configured to cool the insert and workpiece after the at least one insert engagement surface and the at least one opening wall surface engage with one another and plastically deform to form a metallurgical bond between the insert and the workpiece. [Appendix 2] 1. A method for at least partially attaching a tube to a metallic workpiece to at least partially align the tube with at least one opening in the workpiece, the at least one opening being at least partially defined by at least one opening wall having at least one opening wall surface, the method comprising: (a) forming at least one tube engagement surface on a tube configured to engage the at least one opening wall surface; (b) heating the at least one aperture wall surface in a first non-oxidizing atmosphere to a hot working temperature at which the at least one aperture wall surface is plastically deformable; (c) heating the at least one tube-engaging surface in a second non-oxidizing atmosphere to a hot working temperature at which the at least one tube-engaging surface is plastically deformable; and (d) performing an engagement motion on the tube to move the at least one tube engagement surface against the at least one opening wall surface; (e) subjecting the tube to a translational movement while the tube is undergoing the engagement movement and while the at least one tube engagement surface and the at least one aperture wall surface are at a hot working temperature, moving the tube at least partially into the at least one aperture to engage the at least one tube engagement surface with the at least one aperture wall surface while the tube is undergoing the engagement movement to cause plastic deformation as the at least one aperture wall surface and the at least one tube engagement surface engage with one another to at least partially form a metallurgical bond between the tube and the workpiece; (f) cooling the tube and the workpiece to solidify the tube and the workpiece together. [Appendix 3] 1. A method for repairing a workpiece including a defect region, comprising: (a) removing a portion of a workpiece including a defect region to provide an opening in a remainder of the workpiece, the opening being defined by at least one opening wall having at least one opening wall surface in the remainder of the workpiece; (b) providing a first insert including a first insert material capable of metallurgically bonding to metal, the first insert being configured to at least partially fit within at least a portion of the at least one opening and having at least one first insert engagement surface configured to engage with the at least one opening wall surface; (c) heating the at least one aperture wall surface in a first non-oxidizing atmosphere to a hot working temperature at which the at least one aperture wall surface is plastically deformable; (d) heating the at least one first insert mating surface in a second non-oxidizing atmosphere to a hot working temperature at which the at least one first insert mating surface is plastically deformable; (e) performing a first engagement motion on the first insert to move the at least one first insert engagement surface against the at least one opening wall surface; (f) performing a first moving movement of the first insert while the first insert is performing a first engaging movement and while the at least one first insert engaging surface and the at least one opening wall surface are at a hot working temperature, moving the first insert at least partially into the at least one opening to engage the at least one first insert engaging surface with the at least one opening wall surface while the first insert is performing the engaging movement to cause plastic deformation as the at least one opening wall surface and the at least one first insert engaging surface engage with one another to at least partially form a metallurgical bond between the first insert and a remainder of the workpiece; (g) cooling the first insert and a remainder of the workpiece to provide a partially repaired workpiece comprising the first insert and a remainder of the workpiece metallurgically bonded together. [Appendix 4] moreover, (h) forming at least one auxiliary opening in the partially repaired workpiece, the at least one auxiliary opening being defined by at least one auxiliary opening wall located at least partially in a first insert and at least partially in a remainder of the workpiece, the at least one auxiliary opening wall having at least one auxiliary opening wall surface; (i) providing at least one second insert comprising a second insert material capable of metallurgically bonding to metal, said at least one second insert being configured to at least partially fit within said at least one auxiliary opening and having at least one second insert engagement surface configured to engage with a wall surface of said at least one auxiliary opening; (j) heating the at least one auxiliary aperture wall surface in a non-oxidizing atmosphere to a hot working temperature at which the at least one auxiliary aperture wall surface is plastically deformable; (k) heating the at least one second insert mating surface in a non-oxidizing atmosphere to a hot working temperature at which the at least one second insert mating surface is plastically deformable; (l) performing a second engagement motion on the at least one second insert to move the at least one second insert engagement surface relative to the at least one auxiliary opening wall surface; (m) while the at least one second insert is undergoing a second engaging motion and while the at least one second insert engaging surface and the at least one auxiliary opening wall surface are at the hot working temperature, performing a further translation motion of the at least one second insert, moving the at least one second insert at least partially into the at least one auxiliary opening to engage the at least one second insert engaging surface with the at least one auxiliary opening wall surface to induce plastic deformation as the at least one auxiliary opening wall surface and the at least one second insert engaging surface engage one another to at least partially form a metallurgical bond between the at least one second insert and the partially repaired workpiece; and (n) cooling the at least one second insert and the partially repaired workpiece to form a repaired workpiece comprising the at least one second insert and the partially repaired workpiece. [Appendix 5] 5. The method of claim 4, wherein the at least one auxiliary opening is circular. [Appendix 6] 6. The method of claim 5, wherein the at least one second insert is a right circular cone. [Appendix 7] 7. The method of claim 6, wherein the at least one second insert is frustoconical. [Appendix 8] 1. A method of at least partially filling at least one opening in a workpiece, the workpiece comprising at least two layers, each of the at least two layers comprising a metal, the at least one opening being at least partially defined by at least one opening wall, the method comprising: (a) providing an insert including at least two insert materials capable of metallurgically bonding with metals of each of the at least two layers of a workpiece, the insert being configured to at least partially fit within the at least one opening and having at least one insert engagement surface configured to engage with a wall surface of the at least one opening; (b) heating the at least one aperture wall surface in a first non-oxidizing atmosphere to a hot working temperature at which the at least one aperture wall surface is plastically deformable; (c) heating the at least one insert engaging surface in a second non-oxidizing atmosphere to a hot working temperature at which the at least one insert engaging surface is plastically deformable; (d) performing an insert engagement movement to move the at least one insert engagement surface relative to the at least one opening wall surface; (e) performing a translational movement of the insert while the insert is performing the engagement movement and while the at least one insert engagement surface and the at least one aperture wall surface are at a hot working temperature, moving the insert at least partially into the at least one aperture to engage the at least one insert engagement surface with the at least one aperture wall surface while the insert is performing the engagement movement to cause plastic deformation as the at least one aperture wall surface and the at least one insert engagement surface engage with one another to at least partially form a metallurgical bond between the insert and the workpiece; (f) cooling the insert and the workpiece to solidify the insert and the workpiece together.

Claims

1. 1. A method for at least partially filling at least one opening in a metallic workpiece, the at least one opening being at least partially defined by at least one opening wall having at least one opening wall surface, the method comprising: (a) providing an insert comprising an insert material capable of metallurgically bonding to metal, the insert being configured to at least partially fit into said at least one opening and having at least one insert engagement surface configured to engage at least one opening wall surface; (b) disposing at least one aperture surface heating element proximate to the at least one aperture wall surface; (c) disposing at least one insert heating element proximate to the at least one insert engagement surface; (d) using the at least one aperture wall heating element to heat the at least one aperture wall to a hot working temperature in a first non-oxidizing atmosphere to uniformly heat an aperture wall heating layer of the at least one aperture wall to the hot working temperature a first distance from the at least one aperture wall, where the aperture wall heating layer is plastically deformable at the hot working temperature, and where the hot working temperature is below a melting temperature of a metal; (e) heating the at least one insert engaging surface to a hot working temperature in a second non-oxidizing atmosphere with the at least one insert heating element to uniformly heat an insert heating layer of the at least one insert to the hot working temperature a second distance from the at least one insert engaging surface, where the insert heating layer is plastically deformable at the hot working temperature; (f) moving the at least one aperture surface heating element away from the at least one aperture wall surface to allow engagement of the at least one insert engagement surface with the at least one aperture wall surface; (g) moving the at least one insert heating element away from the at least one insert engagement surface to allow engagement of the at least one insert engagement surface with the at least one opening wall surface; (h) performing an engagement movement on the insert to move the at least one insert engagement surface against the at least one opening wall surface; (i) performing a translational movement of the insert while the insert is undergoing an engagement movement and while the insert heating layer and the aperture wall heating layer are at a hot working temperature, moving the insert at least partially into the at least one aperture to engage the at least one insert engagement surface with the at least one aperture wall surface while the insert is undergoing an engagement movement to cause plastic deformation as the aperture wall heating layer and the insert heating layer engage with each other to at least partially form a metallurgical bond between the insert and the workpiece; (j) cooling said insert and said workpiece to solidify said insert and said workpiece together.

2. The method described in claim 1, wherein the engagement motion is a rocking motion relative to the workpiece.

3. The method described in claim 2, wherein the rocking motion is a linear motion of the insert moving relative to the workpiece.

4. The method described in claim 1, wherein the engagement motion is a rotation of the insert relative to the workpiece about the axis of the insert.

5. The method of claim 1, wherein the engagement motion is a vibration motion relative to the workpiece.

6. The method of claim 1 , wherein the at least one opening wall surface is planar and the at least one insert engaging surface is planar.

7. The method described in claim 6, wherein the movement is in a predetermined linear direction to the at least one opening, and the at least one opening wall surface is positioned at a predetermined angle relative to the predetermined linear direction.

8. The method of claim 1, wherein the movement is in a predetermined linear direction toward the at least one opening.

9. The insert extends between its inner and outer ends, The method of claim 1 , wherein the insert has at least one chamfered insert surface at one or more of the inner and outer ends located proximate to the at least one insert engagement surface.

10. the at least one opening wall extends between an inner end and an outer end; 10. The method of claim 9, wherein the workpiece has at least one chamfered workpiece surface at one or more of the inner and outer ends disposed proximate to the at least one opening wall surface.

11. The method of claim 9, wherein the insert has at least one notch formed in its inner end, the notch being capable of partially accommodating the extruded material.

Images