Description: 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.

Benefits: 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).