A method is disclosed for welding a first part and second part together. A spacer bead is first formed on the first part by directing a laser beam on one side of the first part. The second part is then assembled to the one side of the first part. The second part is then welded to the first part by directing a second laser beam in a partially circular pattern adjacent the spacer bead. An end portion of the weld terminates radially inside the partially circular pattern.

Aluminum alloy workpieces and/or magnesium alloy workpieces are joined in a solid state weld by use of a reactive material placed, in a suitable form, at the joining surfaces. Joining surfaces of the workpieces are pressed against the interposed reactive material and heated. The reactive material alloys or reacts with the workpiece surfaces consuming some of the surface material in forming a reaction product comprising a low melting liquid that removes oxide films and other surface impediments to a welded bond across the interface. Further pressure is applied to expel the reaction product and to join the workpiece surfaces in a solid state weld bond.

A galvanized reinforcement beam is continuously formed by uncoiling a roll of galvanized sheet stock in a generally horizontal plane. Protrusions are formed at an upper surface of the sheet stock, which is then roll formed to form a tubular shape with the protrusions abutting a surface of the sheet stock to form venting gaps. The sheet stock is laser welded at the protrusions to continuously form a weld joint, where zinc oxide gas generated from the welding is permitted to escape an interior of the tubular shape through the venting gaps.

A fully automated plasma sheet metal cutter that can be integrated into a HVAC coil-line and which increases the precision of cutting, decreases the time it takes to cut a particular component sheet metal part, and offers flexibility in cutting different sized and shaped holes or openings. Further, since the system is fully automated, it eliminates the error or cost attributed to a portion of the cutting process that heretofore has been associated with a manual laborer.

A method for producing a brake disk for a wheel brake of a land vehicle includes laser depositing a duplex steel anti-corrosion layer to an axial friction side of a main body produced from gray cast iron at a surface speed of more than 10 m/min and applying an anti-abrasion layer to the anti-corrosion layer.

A system for and a method of controlling a filler wire and/or an heat source is provided. The system includes a high intensity energy source configured to heat at least one workpiece to create a molten puddle on a surface of the at least one workpiece. A filler wire feeder is configured to feed a filler wire into said molten puddle, and a travel direction controller is configured to advance the high intensity energy source and the filler wire in a travel direction to deposit the filler wire on the at least one workpiece. The system also includes a controller configured to move the filler wire and/or the energy source in at least a first direction during the feeding and advancing of the filler wire. At least the first direction is controlled to obtain a desired shape, profile, height, size, or admixture of a bead formed by the molten puddle.

A method for producing a thermal barrier coating on a component, more particularly on a turbine component and preferably on a turbine blade, wherein the component is provided with the thermal barrier coating and structures are then created in the outer surface of the thermal barrier coating using a laser ablation process so as to segment the surface of the thermal barrier coating, the structures being created in the surface of the thermal barrier coating by an ultrashort pulse laser, more particularly a femtosecond laser is provided.

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 structure of assembly grasp for palladium-alloy tubes and the manufacturing method thereof are described. The structure of assembly grasp for palladium-alloy tubes includes a grasp with a plurality of holes, a plurality of palladium-alloy tubes inserted into the plurality of holes, and an intermetallic compound layer between the palladium-alloy tubes and the inner sidewalls of the plurality of holes.