A probe for friction stir welding MMCs, ferrous alloys, non-ferrous
alloys, and superalloys, as well as non-ferrous alloys, the probe
including a shank, a shoulder, and a pin disposed through the shoulder
and into the shank, wherein the pin and the shoulder at least include a
coating comprised of a superabrasive material, the pin and shoulder being
designed to reduce stress risers, disposing a collar around a portion of
the shoulder and the shank to thereby prevent movement of the shoulder
relative to the shank, and incorporating thermal management by providing
a thermal flow barrier between the shoulder and the shank, and between
the collar and the tool.