An apparatus (10) for joining a predetermined geometrical profile shape from a sheet material (SM) includes a positioning assembly (12) including a base member (14) and a frame (16) that is operable to receive the sheet material (SM), to configure the sheet material in a predetermined orientation and to linearly translate the sheet material along a process direction (20). A Z-bar (22) is configured to guide a first longitudinal edge (FE) and second longitudinal edge (SE) of the sheet material (SM) into adjacent alignment along the process direction (20). A welding and forging assembly (60) welds and then forges a seam between the first longitudinal edge (FE) and the second longitudinal edge (SE) of the associated sheet material (SM).

An apparatus (10) for joining a predetermined geometrical profile shape from a sheet material (SM) includes a positioning assembly (12) including a base member (14) and a frame (16) that is operable to receive the sheet material (SM), to configure the sheet material in a predetermined orientation and to linearly translate the sheet material along a process direction (20). A Z-bar (22) is configured to guide a first longitudinal edge (FE) and second longitudinal edge (SE) of the sheet material (SM) into adjacent alignment along the process direction (20). A welding and forging assembly (60) welds and then forges a seam between the first longitudinal edge (FE) and the second longitudinal edge (SE) of the associated sheet material (SM).

Systems, methods, and apparatus to weld by preheating welding wire and inductively heating a workpiece are disclosed. An example welding system includes: a welding current source configured to provide welding current to a welding circuit, the welding circuit comprising an electrode wire and a first contact tip of a welding torch; an electrode preheating circuit configured to provide preheating current through a first portion of the electrode wire via a second contact tip of the welding torch; and at least one induction heating coil configured to apply induction heat to a workpiece, the welding current source, the electrode preheating circuit, and the induction heating coil configured to perform a preheating operation and a welding operation on the workpiece.

Systems, methods, and apparatus to weld by preheating welding wire and inductively heating a workpiece are disclosed. An example welding system includes: a welding current source configured to provide welding current to a welding circuit, the welding circuit comprising an electrode wire and a first contact tip of a welding torch; an electrode preheating circuit configured to provide preheating current through a first portion of the electrode wire via a second contact tip of the welding torch; and at least one induction heating coil configured to apply induction heat to a workpiece, the welding current source, the electrode preheating circuit, and the induction heating coil configured to perform a preheating operation and a welding operation on the workpiece.

A method for forming a component includes providing a first layer of a mixture of first and second powders. The method includes determining the frequency of an alternating magnetic field to induce eddy currents sufficient to bulk heat only one of the first and second powders. The alternating magnetic field is applied at the determined frequency to a portion of the first layer of the mixture using a flux concentrator. Exposure to the magnetic field changes the phase of at least a portion of the first powder to liquid. The liquid portion couples to at least some of the second powder and subsequently solidifies to provide a composite component.

A method for forming a component includes providing a first layer of a mixture of first and second powders. The method includes determining the frequency of an alternating magnetic field to induce eddy currents sufficient to bulk heat only one of the first and second powders. The alternating magnetic field is applied at the determined frequency to a portion of the first layer of the mixture using a flux concentrator. Exposure to the magnetic field changes the phase of at least a portion of the first powder to liquid. The liquid portion couples to at least some of the second powder and subsequently solidifies to provide a composite component.

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 seam guide assembly configured to maintain the longitudinal edges of a metal strip in position before welding in a welding section of a welded tube roll forming apparatus, the seam guide assembly having a front seam guide tip component, a through channel being provided in the holder, the channel having an inlet opening located on said first side of the holder, adjacent the front seam guide tip component, and an outlet opening located on a second side of the holder, the outlet opening being configured to connect to a vacuum source; a welded tube roll forming apparatus having a vacuum extraction section configured to extract solid particles produced inside the tube during the high frequency induction welding of the tube edges, and being located in the apparatus at a position where the where the edges of the roll formed tube have not yet been welded together; and related method.

Apparatuses, systems, and/or methods for providing an induction heating system are disclosed. The induction heating system includes an induction power supply and an induction heating tool configured to receive induction-type power from the induction power supply through one or more ports. The ports may be part of the induction power supply and/or an associated junction box. The induction heating tool may include a heating coil attached to one or more plugs via one or more cables. The ports of the induction power supply and/or junction box are configured to receive the plugs of the induction heating tool. A communication device may be positioned adjacent the ports. The communication device may be configured to read data from one or more memory devices of the induction heating tool (e.g., in/on the plugs) via close proximity communication.