A vehicular differential device includes a differential case, a ring gear, and a welded portion positioned on an abutting surface where the differential case and the ring gear are in contact with each other. The welded portion is configured to join the differential case and the ring gear for integral rotation of the differential case and the ring gear around a rotation axis of the vehicular differential device. The welded portion includes a plurality of welding surfaces positioned at predetermined intervals along a circumferential direction around the rotation axis.

A method for manufacturing a metallic article includes providing or obtaining a metallic material in powder form, using an additive manufacturing process, building the metallic article from the powder-form metallic material, layer-by-layer, in a build direction, wherein as a result of the additive manufacturing process, the metallic article comprises columnar grain structures oriented in the build direction, and conveying the metallic article through a gradient furnace in a direction of conveyance from a first area of the gradient furnace to a second area of the gradient furnace to increase a size of the columnar grain structures in the metallic article. The metallic article is conveyed through the gradient furnace in an orientation such that the columnar structures oriented in the build direction are substantially parallel to the direction of conveyance.

A method for additive manufacturing of an article using pressurizing gas in an enclosure including introducing additive manufacturing equipment into the enclosure before sealing and removing air from the sealed enclosure to obtain a predetermined oxygen threshold. Next, the sealed enclosure is pressurized to obtain a predetermined pressure threshold using an inert gas. When the predetermined pressure threshold is obtained, the article is constructed using additive manufacturing.

A method is provided for welding a substrate, in which an energy source and/or a material feed is or are moved in an oscillating motion over the surface of the substrate. The oscillating movement in a vertical and/or horizontal direction during welding results in smaller grains, which prevent the formation of fractures during welding.

A method is provided for manufacturing a segment of a drill string, such as a tubular tool, from a plurality of layers. The method includes arranging a plurality of layers based on a selected length of the segment. Each of the plurality of layers includes an aperture that is received over an alignment feature that restricts movement of the plurality of layers to two or fewer degrees of freedom. A joining process is performed to join the plurality of layers, which may include at least one replacement layer.

A method of fabricating plates of super-hard material and cutting techniques suitable for such a method. A method of fabricating a plate (14) of super-hard material, the method comprising: providing a substrate (4) have a lateral dimension of at least 40 mm; growing a layer of super-hard material on the substrate (4) using a chemical vapor deposition process; and slicing one or more plates (14) of super-hard material from the substrate using a collimated cutting beam (8), the or each plate of super-hard material (14) having a lateral dimension of at least 40 mm, wherein the collimated cutting beam (8) is collimated with a half angle divergence of no more than 5 degrees.

A welding method for welding a cast iron (first member) and a steel (second member) having a lower hardness than the cast iron, which comprises: a first step for inserting an insert material (third member) having a lower hardness than the steel between the cast iron and the steel; a second step for welding the boundary portion between the cast iron and the insert material; and a third step for welding the boundary portion between the steel and the insert material. Consequently, this welding method is able to improve the strength characteristics after welding.

A method of repairing a casing for a gas turbine engine, wherein the casing has a wall extending generally axially, and between at least one radially extending flange, the radially extending flange being formed with a plurality of bolt holes, includes the steps of removing a portion of the flange including at least one bolt hole. The removed portion is associated with a defect and a remaining portion of the flange includes at least one non-removed bolt hole. A replacement portion is obtained to replace the removed portion. The replacement portion is secured in an opening left in the flange by the removed portion. A repaired gas turbine engine casing is also disclosed.

A method for fabricating a main body of a trapped vortex fuel injector having a main body defining a fuel circuit. The method includes determining three-dimensional information of the main body including the fuel circuit where the fuel circuit is fully circumscribed within the main body and extends between an annular portion and a semi-annular portion of the main body and where the three-dimensional information of the main body further includes a plurality of fuel injection ports which provide for fluid communication between the fuel circuit and a trapped vortex pre-mix zone. The method further includes converting the three-dimensional information into a plurality of slices that define a cross-sectional layer of the main body and successively forming each layer of the main body by fusing a metallic powder using laser energy or electron beam energy.

A method of additive manufacture suitable for large and high resolution structures is disclosed. The method may include sequentially advancing each portion of a continuous part in the longitudinal direction from a first zone to a second zone. In the first zone, selected granules of a granular material may be amalgamated. In the second zone, unamalgamated granules of the granular material may be removed. The method may further include advancing a first portion of the continuous part from the second zone to a third zone while (1) a last portion of the continuous part is formed within the first zone and (2) the first portion is maintained in the same position in the lateral and transverse directions that the first portion occupied within the first zone and the second zone.