A method for joining of at least two materials, non-weldable directly to each other with thermal joining processes in a lap joint configuration includes a two step sequence including a first step to apply a thermomechanical or mechanical surface protection layer on the surface of a (stainless) steel substrate and a second step where, a thermal joining process is used to weld the sprayed layer with an applied aluminum sheet without having brittle intermetallic phases in the whole material configuration.

An additive manufacturing system includes an additive manufacturing tool configured to receive a plurality of metallic anchoring materials and to supply a plurality of droplets to a part, and a controller configured to independently control the composition, formation, and application of each droplet to the plurality of droplets to the part. The plurality of droplets is configured to build up the part. Each droplet of the plurality of droplets includes at least one metallic anchoring material of the plurality of metallic anchoring materials.

The present invention relates to a welded structural member having excellent corrosion resistance and crack resistance, and a method for manufacturing same.

The example methods and apparatus reduce and/or eliminate adverse effects of welding work pieces having dissimilar compositions. An example method includes depositing a first weld layer on a first end of a first work piece. The first work piece has a first content of a metallic element and the first weld layer has a second content of the metallic element higher than the first content. The example method includes depositing a second weld layer between the first weld layer and a second end of a second work piece to couple the first work piece to the second work piece. The second weld layer has a third content of the metallic element higher than the second content, and the second work piece has a fourth content of the metallic element higher than the first content.

A lap-joined structure including at least one similar metallic material weldable to each other and a different material different in type from the at least one similar metallic material and difficult to be welded to the similar metallic material. The different material is sandwiched and fixed between the similar metallic material. The similar metallic material has at least one exhaust hole or exhaust groove around the weld zone where the similar metallic material is melted and joined together. The exhaust hole or exhaust groove extends through the similar metallic material along its thickness. Thus, the similar metallic material and the different material are fixed and joined together.

Methods for welding a particle-matrix composite body to another body and repairing particle-matrix composite bodies are disclosed. Additionally, earth-boring tools having a joint that includes an overlapping root portion and a weld groove having a face portion with a first bevel portion and a second bevel portion are disclosed. In some embodiments, a particle-matrix bit body of an earth-boring tool may be repaired by removing a damaged portion, heating the particle-matrix composite bit body, and forming a built-up metallic structure thereon. In other embodiments, a particle-matrix composite body may be welded to a metallic body by forming a joint, heating the particle-matrix composite body, melting a metallic filler material forming a weld bead and cooling the welded particle-matrix composite body, metallic filler material and metallic body at a controlled rate.

An electrical switching device and related methods, for use in aerospace applications include a first static contact assembly, a second static contact assembly, a movable contact assembly for making an electrical connection between the first and second static contact assemblies. The first contact assembly, the second contact assembly and the movable contact assembly each include a silver contact that is percussion welded to the aluminum substrate. Before percussion welding, the silver contact includes a projection for focusing an arc during percussion welding.

A welding method of a diffusion bonded structure in which the diffusion bonded structure formed by diffusion bonding metal parts to each other is bonded to another part by fusion welding includes a buffer layer forming step of forming a buffer layer in a welding region including a diffusion bonded joint of the diffusion bonded structure, the buffer layer having greater ductility than the diffusion bonded joint, and a welding step of bonding the welding region in which the buffer layer is formed to the another part by performing the fusion welding from above the buffer layer.

A method for joining a first part formed of an aluminum material to a second part formed of a steel material by metal inert gas welding and cold metal transfer is provided. An aluminum filler material forms a fillet joint between the parts and provides a structure for automotive body applications, such an aluminum bumper extrusion joined to a steel crush box connection. The first part includes a notch for hiding the start and end of the joint. A transition plate formed of a mixture of aluminum material and steel material can be disposed between the first part and the second part to provide the notch. The second part can include a mechanical fastener further joining the parts together. In another embodiment, the second part includes a plurality of dimples and is welded to the first part along the dimples.

The disclosed technology generally relates to welding, and more particularly to welding multi-layered structures. In an aspect, a method of welding multi-layered metallic workpieces comprises providing a pair of multi-layered workpieces. Each of the workpieces has a base layer and an cladding layer, where the cladding layer comprises a corrosion resistant element adapted to suppress corrosion in a ferrous alloy. The method additionally comprises forming a root pass weld bead to join cladding layers of the workpieces using a first filler wire comprising the corrosion resistant element and focusing a first laser beam on the cladding layers. The method additionally comprises forming one or more weld beads to join base layers of the workpieces by resistively heating a second filler wire and directing a second laser beam over the root pass weld bead. The method is such that a concentration of the corrosion-resistant element in the one or more weld beads is less than 50% of a concentration of the corrosion-resistant element in the root pass weld bead.