Friction Stir Additive Structures With Integrated Tube Passages

The patent applies preliminary action by forming passages during the additive manufacturing process itself rather than after. The friction stir tool creates channels and cavities as the part is being built, allowing passages to be integrated into the part structure from the beginning. This eliminates subsequent attachment steps while achieving structural integration.

The patent merges the passage formation operation with the additive manufacturing process. The friction stir tool simultaneously deposits material and creates passages through its rotation and movement, combining what would traditionally be separate operations into a single integrated process.

The friction stir additive manufacturing process merges material deposition and passage formation into a single operation. As the tool rotates and moves across the substrate, it deposits filler material while simultaneously creating passages through its mechanical action, eliminating the need for separate passage formation steps.

The process maintains continuous useful action by forming passages and depositing material in a continuous operation. The friction stir tool moves continuously across the substrate, constantly depositing material and forming passages without interruption, rather than requiring discrete stopping and starting between operations.

The friction stir tool is pre-configured with specific rotation speeds, depths, and paths to create the desired passage geometry directly during deposition. This preliminary configuration eliminates the need for multiple subsequent machining or finishing operations to achieve precise passage dimensions.

The process controls passage geometry by adjusting parameters of the friction stir tool such as rotation speed, penetration depth, feed rate, and tool path. By changing these parameters, precise passage dimensions and shapes are achieved directly during the additive manufacturing process without requiring additional manufacturing steps.