A process for joining dissimilar materials. The process includes providing a first component made from a first material and a second component made from a second material. The process also includes cold spraying a bead of the second material onto the first component and joining the second component to the bead on the first component such that a weldment is formed from the first component and the second component. In some instances, joining of the second component to the bead on the first component is performed by fusion welding the bead and the second component together.

A process for joining dissimilar materials. The process includes providing a first component made from a first material and a second component made from a second material. The process also includes cold spraying a bead of the second material onto the first component and joining the second component to the bead on the first component such that a weldment is formed from the first component and the second component. In some instances, joining of the second component to the bead on the first component is performed by fusion welding the bead and the second component together.

A welding system comprises a two manipulators and a controller. A first manipulator has a joint detection device and a first welding device, usually of the laser type while the second manipulator has a second welding device, usually of the arc weld type. The joint detection device is operative to read welding joint characteristics along a welding joint. The controller determines a corrected trajectory based on a predetermined welding trajectory and on the welding joint characteristics read by the joint detection device. This corrected trajectory is transmitted with a first time delay to the first manipulator and with a second time delay to the second manipulator. The second time delay is a function of a distance between the joint detection device and the second welding device. A corresponding method for welding components along a welding joint is also disclosed.

A welding system comprises a two manipulators and a controller. A first manipulator has a joint detection device and a first welding device, usually of the laser type while the second manipulator has a second welding device, usually of the arc weld type. The joint detection device is operative to read welding joint characteristics along a welding joint. The controller determines a corrected trajectory based on a predetermined welding trajectory and on the welding joint characteristics read by the joint detection device. This corrected trajectory is transmitted with a first time delay to the first manipulator and with a second time delay to the second manipulator. The second time delay is a function of a distance between the joint detection device and the second welding device. A corresponding method for welding components along a welding joint is also disclosed.

Methods for joining a first blank and a second blank, wherein the first blank and the second blank include a steel substrate with a coating including a layer of aluminum or an aluminum alloy. The method includes selecting a first portion of the first blank to be joined to the second blank, and selecting a second portion of the second blank to be joined to the first portion, and welding the first portion to the second portion. The welding includes using a laser beam and an arc welding torch, wherein the arc welding torch includes a wire electrode, wherein the wire electrode is made of a steel alloy including gammagenic elements, optionally a stainless steel alloy including gammagenic elements and displacing both the laser beam and the arc welding torch in a welding direction, and wherein in the welding direction, the arc welding torch is positioned in front of the laser beam.

Methods for joining a first blank and a second blank, wherein the first blank and the second blank include a steel substrate with a coating including a layer of aluminum or an aluminum alloy. The method includes selecting a first portion of the first blank to be joined to the second blank, and selecting a second portion of the second blank to be joined to the first portion, and welding the first portion to the second portion. The welding includes using a laser beam and an arc welding torch, wherein the arc welding torch includes a wire electrode, wherein the wire electrode is made of a steel alloy including gammagenic elements, optionally a stainless steel alloy including gammagenic elements and displacing both the laser beam and the arc welding torch in a welding direction, and wherein in the welding direction, the arc welding torch is positioned in front of the laser beam.

A method of making a heat exchanger includes arranging a plurality of tubes in a formation; welding the plurality of tubes to a header by welding each tube of the plurality of tubes to a respective header slot of a plurality of header slots in the header; coupling a cover to a liquid-side surface of the header to cover an end of each tube of the plurality of tubes; applying flux to an air-side surface of the header and to the plurality of tubes; removing the cover from the header; and brazing each tube of the plurality of tubes to the respective header slot of the plurality of header slots.

An example method for joining metals is described herein. The method can include forming an intermediate joint between a light metal member and a metal insert, where the intermediate joint is formed using a solid state welding process. The method can also include forming a primary joint between the light metal member and a high strength steel member, where the primary joint is formed using a welding process that produces coalescence at a temperature above the melting point of the light metal member and/or the high-strength steel member.

Device (1) including a head (5) for induction pre-heating the adjacent edges of at least one item requiring welding which have to be joined, in which a sliding-block-shaped supporting structure (8) capable of moving above the edges to be welded (2, 3) and parallel thereto carries a first U-shaped inductor (9) in a first plane parallel to a plane containing the edges which have to be welded and carries a second inductor (14) which is U-shaped in a second plane perpendicular to the first plane in such a way that a first and second branch (16, 17) respectively of a tube (15) of the second inductor (14) are placed between the edges which have to be welded, at a predetermined distance (K) from the first inductor (9), when in use.

Device (1) including a head (5) for induction pre-heating the adjacent edges of at least one item requiring welding which have to be joined, in which a sliding-block-shaped supporting structure (8) capable of moving above the edges to be welded (2, 3) and parallel thereto carries a first U-shaped inductor (9) in a first plane parallel to a plane containing the edges which have to be welded and carries a second inductor (14) which is U-shaped in a second plane perpendicular to the first plane in such a way that a first and second branch (16, 17) respectively of a tube (15) of the second inductor (14) are placed between the edges which have to be welded, at a predetermined distance (K) from the first inductor (9), when in use.