M. W. Mahoney, C. Fuller, B. Bingel, Rockwell Scientific, Thousand Oaks, CA; K. Anderson, California State University San Luis Obispo, San Luis Obispo, CA

Summary: A consumable friction plugging (welding) technique has been developed to plug the tool exit hole associated with friction stir welding/processing (FSW/P) of NiAl bronze. One of the most convenient and cost effective methods to fill the exit hole is a consumable plug. Results will be reported illustrating process development including 1) special preparation of the exit hole, 2) design of the consumable, 3) evaluation of plug material, i.e., wrought, cast, and friction stir processed, and 4) a three step plugging procedure. Microstructures developed are presented illustrating integrity of the bond interface with different approaches. Further, mechanical properties across the plug interface and corrosion sensitivity of the surface at the plug location are reported for the different approaches.