A method for forming an impact weld used in an additive manufacturing process. The method includes providing a wire having a powder filler metal core located within a sheath. The wire is then inserted within a conduit having an opening. Further, the method includes providing at least one energy pulse that interacts with the sheath to pinch off at least one segment of the wire, wherein the energy pulse causes propulsion of the segment toward a substrate with sufficient velocity to form an impact weld for welding the metal core to the substrate. In particular, the energy pulse is an electromagnetic pulse, a laser energy pulse or a high electric current pulse.

Disclosed herein is an article comprising a first metal layer; a second metal layer that is chemically different from the first metal layer; and a third metal layer disposed between the first metal layer and the second metal layer and contacting both the first metal layer and the second metal layer; where the third metal layer is chemically similar to either the first metal layer or the second metal layer; where at least two metal layers that are chemically similar are welded together through a clearance opening located in a metal layer that is not chemically similar to the at least two metal layers.

Disclosed herein is an article comprising a first metal layer; a second metal layer that is chemically different from the first metal layer; and a third metal layer disposed between the first metal layer and the second metal layer and contacting both the first metal layer and the second metal layer; where the third metal layer is chemically similar to either the first metal layer or the second metal layer; where at least two metal layers that are chemically similar are welded together through a clearance opening located in a metal layer that is not chemically similar to the at least two metal layers.

A wire-feeding electromagnetic spray additive manufacturing device and method are provided. The device includes a housing, an alternating current power box is fixedly installed on the housing, and a stirring needle is also arranged in the housing. The device further includes a fixed seat fixedly installed in the housing, and a heating coil is arranged between the fixed seat and the stirring needle; a lower end of the stirring needle is provided with spinnerets and heating channels adapted with corresponding the spinnerets respectively; upper ends of the heating channels penetrate through the stirring needle and are fixedly connected with the housing, and an extrusion assembly is fixedly installed on each of the heating channels; and a smoke pipe is fixedly installed on the extrusion assembly, and an upper end of the smoke pipe penetrates through the housing and is connected with a negative pressure fan.

A wire-feeding electromagnetic spray additive manufacturing device and method are provided. The device includes a housing, an alternating current power box is fixedly installed on the housing, and a stirring needle is also arranged in the housing. The device further includes a fixed seat fixedly installed in the housing, and a heating coil is arranged between the fixed seat and the stirring needle; a lower end of the stirring needle is provided with spinnerets and heating channels adapted with corresponding the spinnerets respectively; upper ends of the heating channels penetrate through the stirring needle and are fixedly connected with the housing, and an extrusion assembly is fixedly installed on each of the heating channels; and a smoke pipe is fixedly installed on the extrusion assembly, and an upper end of the smoke pipe penetrates through the housing and is connected with a negative pressure fan.

A composite engine component comprises a body having an outer circumferential surface and an inner circumferential surface. The body of the engine component is of unitary, integral, one-piece construction and comprises a radially inner section and a radially outer section having different material compositions. The radially inner section and the radially outer section of the body are welded together using a magnetic pulse welding process in which a metallurgical bond is formed along a bonding interface between the inner and outer sections of the body.

A composite engine component comprises a body having an outer circumferential surface and an inner circumferential surface. The body of the engine component is of unitary, integral, one-piece construction and comprises a radially inner section and a radially outer section having different material compositions. The radially inner section and the radially outer section of the body are welded together using a magnetic pulse welding process in which a metallurgical bond is formed along a bonding interface between the inner and outer sections of the body.

In a first embodiment, at a time of magnetic pulse welding, a stepped tube profile machining process axially bores a walled tube from an end inward to a transition depth to form a section with a reduced wall thickness and then axially bores the walled tube from the transition depth to a fall off depth, thereby forming a section with a maximized welding wall section. In a second embodiment, also at a time of magnetic pulse welding, a surface angle tube profile machining process axially bores at a surface angle a walled tube from an end to a bore length to form an angular welding wall thickness inward to a maximized wall section. For both embodiments, the bored surfaces are virgin with no pits, oil, residue, or oxidation thereon, thus making the machined walled tubes available for immediate magnetic pulse welding.

In a first embodiment, at a time of magnetic pulse welding, a stepped tube profile machining process axially bores a walled tube from an end inward to a transition depth to form a section with a reduced wall thickness and then axially bores the walled tube from the transition depth to a fall off depth, thereby forming a section with a maximized welding wall section. In a second embodiment, also at a time of magnetic pulse welding, a surface angle tube profile machining process axially bores at a surface angle a walled tube from an end to a bore length to form an angular welding wall thickness inward to a maximized wall section. For both embodiments, the bored surfaces are virgin with no pits, oil, residue, or oxidation thereon, thus making the machined walled tubes available for immediate magnetic pulse welding.

A valve for a valve device may include a valve stem, which in an axial direction relative to a valve stem axis merges into a valve disc projecting from the valve stem radially. A valve cap may be included composed of a metal. The valve cap may be attached to an axial end portion of the valve stem facing away from the valve disc. The valve cap may cover a face end of the valve stem facing away from the valve disc and may envelope the axial end portion of the valve stem at least partially.