A linear friction welding method capable of accurately controlling a welding temperature and capable of lowering the welding temperature is provided. The present invention is a linear friction welding method comprising: a first step of forming a welded interface by bringing one member into contact with the other member; a second step of repeatedly sliding one member and the other member on the same locus and discharging flash from the welded interface in a state where pressure is applied substantially perpendicularly to the welded interface; and a third step of forming a welded surface by stopping the sliding and setting the pressure to be not less than the yield stress and not more than the tensile strength of one member and/or the other member at a desired welding temperature.

Provided are a busbar unit and a method of manufacturing thereof configured to prevent an increase in resistance at a connection portion therebetween, to provide a good connection condition, and to easily achieve even a complicated wiring structure, in the case of connecting between a busbar and a pre-welded member (a terminal, another busbar, or the like) made of a metal material different from that of the busbar. A busbar unit includes a busbar made of a first metal material, and a welded member made of a second metal material to be connected to an end portion of the busbar. A welded portion between the end portion of the busbar and the welded member is configured by pressure welding between end surfaces butted against each other.

Solid-state additive and subtractive manufacturing processes, completely or partially performed by a solid-state manufacturing system, are disclosed. Solid-state deposition processes of different materials for printing 3D parts, coating, joining or repair are included as examples. Subtractive processing steps, such as machining, drilling, surface grooving, surface activation and others are discussed as well. In addition, other processes performed by other means are mentioned in making the final parts.

According to one aspect, the present disclosure provides a system for manufacturing transition structures including fiber threads embedded within a metal component. The system may include a supply of base sheet metal. The system may include a conveyor supported on a plurality of rollers and configured to move the base sheet metal in a production direction. The system may include a plurality of stages arranged in the production direction. Each stage may include a channel forming device configured to form a channel in the base sheet metal, a fiber inserting device configured to insert a portion of a fiber material into the channel, and one or more ultrasonic welders configured to consolidate a layer of metal foil over the fiber. The disclosure includes methods of using the system to produce transition structures and reinforced components.

A method includes moving a first part along a movement path. The method also includes introducing drops of a liquid metal onto the first part using a three-dimensional (3D) printer. The drops of the liquid metal solidify to form a second part that is joined to the first part. The method also includes mechanically joining the second part to a third part.

A method of forming a canister by means of a mechanical bonding of respective layers of a first metal material (tantalum) and a second metal material (niobium) to form a sheet stock, thereby forming the sheet stock into a canister form, wherein the first metal material comprises tantalum and the second metal material comprises at least one of niobium, molybdenum, or steel. The completed canister comprises a first metal material comprising tantalum, and a second metal material mechanically bonded to the first metal material by subjecting the first and second metal materials to at least 1,000,000 psi, to thereby form a canister having an inner diameter of 13-19 millimeters (mm), the second metal material comprising at least one of niobium, molybdenum, or steel.

A friction stir spot welding apparatus including a controller that (A) operates a rotary driver and a tool driver such that a pin and a shoulder are brought into contact with a welded workpiece; (B) operates, after the (A), the rotary driver and the tool driver such that the pin separates from the welded workpiece; and (C) operates, after the (B), the rotary driver and the tool driver such that the pin advances toward the welded workpiece. The controller controls the tool driver such that pressing force applied to the welded workpiece from the pin and the shoulder in the (C) is smaller than that in the (B) and/or controls the rotary driver such that rotational frequencies of the pin and the shoulder in the (C) are lower than those in the (B).

Methods of manufacturing or repairing a turbine blade or vane are described. The airfoil portions of these turbine components are typically manufactured by casting in a ceramic mold, and a surface made up of the cast airfoil and at the least the ceramic core serves as a build surface for a subsequent process of additively manufacturing the tip portions. The build surface is created by removing a top portion of the airfoil and the core, or by placing an ultra-thin shim on top of the airfoil and the core. The overhang projected by the shim is subsequently removed. These methods are not limited to turbine engine applications, but can be applied to any metallic object that can benefit from casting and additive manufacturing processes. The present disclosure also relates to finished and intermediate products prepared by these methods.

Methods of manufacturing or repairing a turbine blade or vane are described. The airfoil portions of these turbine components are typically manufactured by casting in a ceramic mold, and a surface made up of the cast airfoil and at the least the ceramic core serves as a build surface for a subsequent process of additively manufacturing the tip portions. The build surface is created by removing a top portion of the airfoil and the core, or by placing an ultra-thin shim on top of the airfoil and the core. The overhang projected by the shim is subsequently removed. These methods are not limited to turbine engine applications, but can be applied to any metallic object that can benefit from casting and additive manufacturing processes. The present disclosure also relates to finished and intermediate products prepared by these methods.

The invention relates to a method for connecting at least two component layers by means of a connection element. the invention to provide a particularly advantageous method for connecting at least two component layers lying on top of each other through the creation of a pilot hole in at least one cover layer. The pilot hole in the form of a through hole is made in the at least one cover layer using only a plasma jet, which cover layer is at least temporarily held in place on the base layer. Holding the cover layer and the base layer temporarily fixed to each other will allow the connection element to be placed at the same position in the base layer where the pilot hole is made. Sufficiently large layers can thus be kept in a fixed position relative to one another solely using their weight and friction.