A welding method includes feeding a welding electrode axially from a welding torch, moving the welding electrode radially in a desired pattern with respect to a central axis of the welding torch by a motion control assembly within the welding torch, transmitting from control circuitry a signal corresponding to a position of the welding electrode relative to a weld joint or weld pool, advancing the welding torch or a workpiece to establish a weld, and transferring material from the welding electrode to a first location in an area of the weld pool. The welding electrode moves radially while feeding the welding electrode from the welding torch, the material from the welding electrode is transferred to the first location during a first cycle of the desired pattern, and the first location is controlled based at least in part on the signal.

Second member (20) includes a material that is difficult to weld to first member (10). First member (10) is provided with first penetrating part (11) penetrating in a thickness direction. Third member (30) is arc-welded to an inner peripheral surface of first penetrating part (11) and opening surface (10a) of first member (10) via second penetrating part (21) of second member (20). Second member (20) is compressed by flange (31) and first member (10) by solidification contraction of third member (30), and second member (20) is therefore fixed between flange (31) of third member (30) and first member (10).

Second member (20) includes a material that is difficult to weld to first member (10). First member (10) is provided with non-through hole (11) having a depth not penetrating in a thickness direction. Third member (30) is welded, via penetrating part (21) of second member (20), to an inner peripheral surface and a bottom of non-through hole (11) and opening surface (10a) of first member (10) opened by penetrating part (11) of second member (20). Second member (20) is compressed by flange (31) and first member (10) by solidification contraction of third member (30), and second member (20) is therefore fixed between flange (31) of third member (30) and first member (10).

Second member (20) includes a material that is difficult to weld to first member (10). First member (10) is provided with non-through hole (11) having a depth not penetrating in a thickness direction. Third member (30) is welded, via penetrating part (21) of second member (20), to an inner peripheral surface and a bottom of non-through hole (11) and opening surface (10a) of first member (10) opened by penetrating part (11) of second member (20). Second member (20) is compressed by flange (31) and first member (10) by solidification contraction of third member (30), and second member (20) is therefore fixed between flange (31) of third member (30) and first member (10).

Methods of ultrasound assisted 3D printing and welding involve the use of an ultrasonic sonotrode placed in on top of the solidified layer in the vicinity of a melt pool. The sonotrode, pressed against the solidified materials at the edge of the melt pool, is synchronized with the heat source such that it travels side-by-side with the melt pool to transmit ultrasonic vibrations to the solidifying melt pool, reducing hot tearing and porosity formation, and to consolidate the solidified materials under the sonotrode. The methods of the present invention are capable of making a large variety of commercially important alloys 3D printable and weldable.

In certain embodiments, inductive heating is added to a metal working process, such as a welding process, by an induction heating head. The induction heating head may be adapted specifically for this purpose, and may include one or more coils to direct and place the inductive energy, protective structures, and so forth. Productivity of a welding process may be improved by the application of heat from the induction heating head. The heating is in addition to heat from a welding arc, and may facilitate application of welding wire electrode materials into narrow grooves and gaps, as well as make the processes more amenable to the use of certain compositions of welding wire, shielding gasses, flux materials, and so forth. In addition, distortion and stresses are reduced by the application of the induction heating energy in addition to the welding arc source.

In certain embodiments, inductive heating is added to a metal working process, such as a welding process, by an induction heating head. The induction heating head may be adapted specifically for this purpose, and may include one or more coils to direct and place the inductive energy, protective structures, and so forth. Productivity of a welding process may be improved by the application of heat from the induction heating head. The heating is in addition to heat from a welding arc, and may facilitate application of welding wire electrode materials into narrow grooves and gaps, as well as make the processes more amenable to the use of certain compositions of welding wire, shielding gasses, flux materials, and so forth. In addition, distortion and stresses are reduced by the application of the induction heating energy in addition to the welding arc source.

A method of manufacturing a welded structure of a ferritic heat-resistant steel is provided that prevents Type IV damage and that has good on-site operability without adding a high B concentration. The method includes: the step of preparing a base material including 8.0 to 12.0% Cr, less than 0.005% B and other elements; the step of forming an edge on the base material; a pre-weld heat treatment step in which a region located between a surface of the edge and a position distant from the surface of the edge by a pre-weld heat treatment depth of 30 to 100 mm is heated to a temperature of 1050 to 1200° C. and is held at this temperature for 2 to 30 minutes; a welding step in which the edge is welded to form the weld metal; and a post-weld heat treatment step in which a region located between the surface of the edge and a position distant from the surface of the edge by a distance not smaller than the pre-weld heat treatment depth and not greater than 100 mm is heated to a temperature of 720 to 780° C. and is held at this temperature for a time period not shorter than 30 minutes and satisfying the following formula, (1):
(Log(t)+12).Math.(T+273)<13810  (1).

A method of manufacturing a welded structure of a ferritic heat-resistant steel is provided that prevents Type IV damage and that has good on-site operability without adding a high B concentration. The method includes: the step of preparing a base material including 8.0 to 12.0% Cr, less than 0.005% B and other elements; the step of forming an edge on the base material; a pre-weld heat treatment step in which a region located between a surface of the edge and a position distant from the surface of the edge by a pre-weld heat treatment depth of 30 to 100 mm is heated to a temperature of 1050 to 1200° C. and is held at this temperature for 2 to 30 minutes; a welding step in which the edge is welded to form the weld metal; and a post-weld heat treatment step in which a region located between the surface of the edge and a position distant from the surface of the edge by a distance not smaller than the pre-weld heat treatment depth and not greater than 100 mm is heated to a temperature of 720 to 780° C. and is held at this temperature for a time period not shorter than 30 minutes and satisfying the following formula, (1):
(Log(t)+12).Math.(T+273)<13810  (1).

A system may include a current source; a first metal or alloy component with a first major surface electrically coupled to the current source; a second metal or alloy component with a second major surface electrically coupled in series to the first component and the current source via an external electrical conductor, where the first and second major surfaces are positioned adjacent to each other to define a joint region; a metal or alloy powder disposed in at least a portion of the joint region; and a controller. The controller may be configured to cause the current source to output an alternating current that conducts through the first component and the second component to induce magnetic eddy currents, magnetic hysteresis, or both within at least a portion of the metal or alloy powder disposed in at least the first portion of the joint region.