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A non weldable to weldable (N2W) methodology is presented in which friction stir welding (FSW) is used to join a non weldable (but highly wear resistant) material to a weldable material (e.g. a steel insert positioned within the wear resistant material) to create a subassembly that can be subsequently welded to the final structure. Subassemblies, comprising steel inserts positioned into pre-machined engineered cavities in wear resistant cemented carbide, were fabricated by FSW using the MegaStir gantry system and polycrystalline BN, 30%WRe Q70 tools with a convex step spiral scroll shoulder design. The composite subassembly was friction stir welded onto the exterior of a drilling stabiliser. Issues discussed include process parameters used in welding the subassembly onto the stabiliser body and the benefits of N2W for fabricating the drilling stabiliser.

11th International Symposium, 17-19 May 2016, Session 9A: Techniques III, Paper 01