In aerospace applications, Friction Stir Welding (FSW) has emerged as a good choice for joining aluminum. This solid-state process relies on a rotating cylindrical tool to generate enough localized heat and pressure to create a continuous weld as the tool translates through the joint. In his paper at Great Designs In Steel, Tsung-Yu Pan and co-authors from two of our national laboratories detailed a FSW variant that shows promise for AHSS. Friction Stir Spot Welding (FSSW) creates spot welds rather than a linear weld line. It has successfully been in production on aluminum components since 2003. Pan's presentation shows that it may be a good fit for AHSS too. Studies on an increasingly popular AHSS, DP 780, showed that the FSSW produced spot welds with 8-12 kN strengths, comparable with JIS standards. The bonding region showed similar microstructure and hardness to the base material. And all this comes without any attempt to optimize the materials or process.
A make-your-own Star Wars Sith Lightsaber hilt is heftier and better-looking than most others out there, according to its maker, Sean Charlesworth. You can 3D print it from free source files, and there's even a hardware kit available -- not free -- so you can build one just in time for Halloween.
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