A method and apparatus for applying a cladding layer to a surface of a component uses a cladding tool having a maximum reach less than the size of the surface. Geometry of the surface is segmented into a plurality of tessellated segments, each of which has a peripheral extent determined by a maximum reach of the cladding tool. A nominal tool subpath for each tessellated segment is generated, and then combined to generate a nominal tool path for depositing the cladding layer on the surface. The surface is clad using the nominal toolpath, including a process of adjusting the nominal tool path to an adjusted tool path that accounts for dimensions of the bead to be deposited by the tool to match an edge of the bead to be deposited with an edge of a previously deposited bead.

A lap fillet weld joint and a lap fillet weld joint manufacturing method are provided. On a side of a first edge, a first metal plate is provided with a bulging portion that has an internal space of a prescribed size, and a second metal plate has a protruding portion that faces to the bulging portion and can be inserted into the bulging portion. In a state in which the protruding portion has been inserted into the bulging portion, the first metal plate and a second edge of the second metal plate are welded, and a first weld bead is formed.

Second member (20) includes a material that is difficult to weld to first member (10). First member (10) is provided with first penetrating part (11) penetrating in a thickness direction. Third member (30) is arc-welded to an inner peripheral surface of first penetrating part (11) and opening surface (10a) of first member (10) via second penetrating part (21) of second member (20). Second member (20) is compressed by flange (31) and first member (10) by solidification contraction of third member (30), and second member (20) is therefore fixed between flange (31) of third member (30) and first member (10).

An additive manufacturing system includes an electrode head comprising an array of electrodes for depositing material to form a three-dimensional attachment structure connecting first and second prefabricated metallic parts. The array includes a first plurality of electrodes formed from a first metallic material having a first ductility and a first hardness, and a second plurality of electrodes formed from a second metallic material having a second ductility and a second hardness, wherein the first ductility is greater than the second ductility and the second hardness is greater than the first hardness. A power source provides power for heating each electrode. A drive roll system drives each electrode. A controller is connected to the power source to control operations of the additive manufacturing system to form an interior portion of the attachment structure using the first plurality of electrodes, and control the operations of the additive manufacturing system to form an exterior portion of the attachment structure using the second plurality of electrodes, such that ductility of the interior portion of the attachment structure is greater than ductility of the exterior portion of the attachment structure.

Second member (20) includes a material that is difficult to weld to first member (10). First member (10) is provided with non-through hole (11) having a depth not penetrating in a thickness direction. Third member (30) is welded, via penetrating part (21) of second member (20), to an inner peripheral surface and a bottom of non-through hole (11) and opening surface (10a) of first member (10) opened by penetrating part (11) of second member (20). Second member (20) is compressed by flange (31) and first member (10) by solidification contraction of third member (30), and second member (20) is therefore fixed between flange (31) of third member (30) and first member (10).

The disclosure relates to the field of wire arc additive manufacturing, and specifically discloses a wire arc additive manufacturing method for a high-strength aluminum alloy component, equipment and a product. A high-strength aluminum alloy is modified by using a MXene nanomaterial, and wire arc additive manufacturing is performed by using the modified high-strength aluminum alloy as a raw material, and a nanosecond laser beam is applied during the wire arc additive manufacturing to achieve an enhanced arc cathode atomization cleanup function to remove impurities, thus obtaining a high-strength aluminum alloy component without defects. The disclosure can solve the problem of very difficult forming in wire arc additive manufacturing of a high-strength aluminum alloy, and also solve the problems of many pores, liability to crack and lots of impurities during additive manufacturing of the high-strength aluminum alloy, so that a high-strength aluminum alloy component without defects can be produced.

The present disclosure relates to the technical field of dissimilar welding of Cu and a steel, and in particular to a welding wire for dissimilar welding of Cu and a steel and a preparation method thereof and a method for welding Cu and a steel. The present disclosure provides a welding wire for dissimilar welding of Cu and a steel, including, in percentages by mass, 5-25% of iron phase, less than 0.1% of inevitable impurities, and copper matrix. The welding wire of the present disclosure, containing two elements, i.e. copper and iron, is conducive to the mixing of the two phases—copper and iron—during the welding process, to form a mutual soluble region, thereby makes it possible to greatly increase the weldability, reduce the width of the weld, effectively overcome the tendency of cracks, and thus to ensure the formed weld with a high crack resistance.

A hybrid bumper assembly for a vehicle includes a steel reinforcement beam and aluminum crush cans attached to end portions of the steel reinforcement beam. The reinforcement beam has a multi-tubular shape that is formed by a high-strength steel sheet that is roll formed to provide at least two tubular portions. A crush can has an interfacing portion that is coupled to an end portion of the reinforcement beam. The end portions of the reinforcement beam and the interfacing portion of the crush cans may be configured to attach together using a select joining technology in a manner that minimizes or eliminates bimetallic or galvanic corrosion between the reinforcement beam and the crush cans.

Method for producing a component system having a first component with a first component portion and a second component with a second component portion, including the following steps: connecting, in particular welding or soldering, the first component portion, which consists of an aluminum alloy, to the second component portion, which in particular consists of a naturally aged aluminum alloy, a copper alloy or an iron alloy, in particular a steel alloy, so as to form a connection seam; artificially aging the connection seam such that the yield strength of the connection seam is above the yield strength of the first component portion and/or of the second component portion; and deforming, in particular deep-drawing and/or stretch-drawing, the component system.

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.