Friction stir welding process having enhanced corrosion performance

Abstract: A three dimensional joint is formed by coupling (joining) a first structural member and a second structural member. This involves first aligning a first structural member to a second structural member. The first structural member has a channel with which to receive a portion of the second structural member. Certain embodiments may place corrosively inert materials within the mating surfaces to prevent or inhibit corrosion or oxidation. Once aligned, the first structural member and second structural member may be friction stir welded at the channel to plasticize the material adjacent to the channel of both the first structural member and the second structural member to form a friction stir weld joint. Embodiments may then coat the plasticized surfaces of the FSW joint with cold sprayed materials to inhibit corrosion. Should a crack occur within either the plasticized or non-plasticized materials, cold sprayed material may be deposited within and on the crack to retard or arrest the growth of the crack.