A method of forming a sealed joint between a tubular article (10) and a thin sheet article (14) wherein the articles (10, 14) are made of metallic materials that are capable of fusion welding together. One step in the method involves locating an end of the tubular article in a collar (20) surrounding a hole (12) formed in the thin sheet article (14). An end (22) of the tubular article (14) is positioned to lie substantially flush with a proximal end (24) of the collar (20). Next the ends (22, 24) of the collar and the tubular article are fusion welded forming a circumferential bead (26) creating an integral joint. Consequently in effect the previously separate a tubular article (10) and a thin sheet article (14) become a single piece.

A sprocket wheel, which is a machine component configured to slide relative to a bushing while being in contact with the bushing in an outer peripheral surface, includes a base made of a first metal, and an overlay that covers the base so as to constitute the outer peripheral surface. The surface of the overlay constituting the outer peripheral surface has been smoothed. Such a smoothed surface of the overlay makes the sprocket wheel less damaging to the bushing.

A non-weldable workpiece may be affixed to a weldable workpiece by friction stirring the weldable workpiece to plasticize and extrude at least a portion thereof into a recess in the non-weldable workpiece. The weldable workpiece may then be welded to a body of a downhole tool to enable the welding of a non-weldable workpiece onto a body to increase the wear-resistance of the body.

A method of manufacturing a highly insulating three-dimensional (3D) structure is provided. The method includes depositing a first layer of hollow microspheres onto a base. The hollow microspheres have a metallic coating formed thereon. A laser beam is scanned over the hollow microspheres so as to sinter the metallic coating of the hollow microspheres at predetermined locations. At least one layer of the hollow microspheres is deposited onto the first layer. Scanning by the laser beam is repeated for each successive layer until a predetermined 3D structure is constructed. The 3D structure includes a composite thermal barrier coating (TBC), which may be applied to a surface of components within an internal combustion engine, and the like. The composite TBC is bonded to the components of the engine to provide low thermal conductivity and low heat capacity insulation that is sealed against combustion gasses.

A hybrid article is disclosed including a coating circumscribing the lateral surface of a hollow core having a core material and a channel disposed within the lateral surface. The coating includes about 35% to about 95% of a first metallic material, and about 5% to about 65% of a second metallic material with a lower melting point than the first metallic material. A method for forming the hybrid article is disclosed including disposing the hollow core in a die, forming a gap between the lateral surface and the die, introducing a slurry having the metallic materials into the gap, and sintering the slurry, forming the coating. A method for closing an aperture of an article is disclosed including inserting the hybrid article into the aperture, and brazing the hybrid article to the article, welding the aperture with the hybrid article serving as weld filler, or a combination thereof.

A heavy weight drill pipe for use in a downhole tool. The heavy weight drill pipe may include a tool joint made of a first steel alloy selected from the group consisting of AISI 4135, AISI 4137, AISI 4140, AISI 4142, AISI 4145, and AISI 4147. The tool joint may have as radial thickness between about 3.0 cm and about 5.7 cm. The heavy weight drill pipe may also include a pipe made of a second steel alloy selected from the group consisting of AISI 4135, AISI 4137, AISI 4140, AISI 4142, AISI 4145, and AISI 4147. The pipe may have a radial thickness between about 1.6 cm and about 3.3 cm. A weld region may be formed between the tool joint and the pipe. The weld region may be formed by friction welding the tool joint to the pipe.

A method for brazing is provided, in which an amorphous or partially amorphous brazing foil, having a composition with a metalloid content of 10 to 30 at. %, is arranged at a joining point of two or more parts. The brazing foil is in the form of a wound ring-shaped strip which has a short-circuited current path between at least two layers lying one on top of the other. The brazing foil inductively heated, melted and a brazed connection of the parts is produced.

A method for fixing a strip end segment of a metal strip wound into a coil to a strip winding of the coil arranged adjacent to the strip end segment. In order to enable the production of metal strip with improved quality, the strip end segment is fixed by materially bonding on the strip winding by means of a friction welding method.

A device for welding together cylindrical sections of a casing. The device comprises a clamping ring configured to surround and attach to a section of the casing and a robot provided with a welding gun and at least one joint, wherein the robot is movably attached to the clamping ring by cooperating means. A method for welding cylindrical sections of a casing by using such a device includes the steps of a) positioning and clamping the clamping ring at the correct position, b) moving the robot along the clamping ring to the correct position for welding, c) welding the sections to each other by the welding gun of the robot, and d) releasing the clamping ring.

A process for manufacturing a muffler for an exhaust system of an internal combustion engine, provides a manufactured muffler with a muffler housing with a housing jacket (14) that is elongated in a direction of a housing longitudinal axis and with at least one housing bottom (26) carried on the housing jacket (14). The process includes the steps of providing the housing jacket (14) with a stop formation (50) in association with at least one housing bottom (26) to be carried on the housing jacket (14), providing the at least one housing bottom (26) to be carried on the housing jacket (14), and positioning the at least one housing bottom (26) on the housing jacket (14) such that the housing bottom (26) is in contact with the stop formation (50) associated with the housing bottom (26).