A method of gas metal arc welding, (GMAW) an Inconel part to a stainless steel part, including forming a weldable joint between a first surface of the Inconel part having a first thickness and a second surface of a stainless steel part having a second thickness at the weldable joint that is greater than the first thickness, welding the Inconel part to the stainless steel part along the weldable joint with the welding torch, delivering an output from the welding power source to the welding torch during welding, wherein the output of the welding power source is in the range of 100 amps to 400 amps and in the range of 14 volts to 30 volts, and delivering a continuous weld wire to a distal tip of the welding torch during welding, wherein a feed rate of the weld wire is in the range of 3 m/min. to 9 m/min.

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.

A welded joint comprising an aluminum-based base material comprising an aluminum alloy or pure aluminum and a copper-based base material comprising a copper alloy or pure copper joined by a weld metal portion is provided. The weld metal portion contains copper in ranges of less than 75% by mass and silicon in ranges of less than 13% by mass and has a higher content of copper and silicon than the aluminum-based base material.

An additive manufacturing system includes an additive manufacturing tool configured to supply a plurality of droplets to a part, a temperature control device configured to control a temperature of the part, and a controller configured to control the composition, formation, and application of each droplet to the plurality of droplets to the part independent from control of the temperature of the part via the temperature control device. 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.

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 present invention relates to an arc welding method for dissimilar material joining for joining a first plate made of an aluminum alloy or a magnesium alloy and a second plate made of steel. A steel-made joining assist member has a stepped external shape including a large-diameter portion and a small-diameter portion, has a hollow portion formed to penetrate the large-diameter portion and the small-diameter portion, and has a total height of the large-diameter portion and the small-diameter portion being equal to or larger than a thickness of the first plate. A pressure is applied to the joining assist member to punch the first plate. The hollow portion of the joining assist member is filled with a weld metal. The weld metal is melted until a penetration bead is formed on the second plate, to weld the second plate and the joining assist member together.

A dissimilar-metal joining tool that places a ring-shaped joining auxiliary member made of iron, on a surface of a workpiece in which a second metal plate made of non-ferrous metal is laminated on a first metal plate made of iron, coaxially with a through-hole penetrates the second metal plate, and that performs arc welding toward an inner hole of the joining auxiliary member, the dissimilar-metal joining tool includes a base attached to a distal end of a robot; an arc welding torch attached to the base; a positioning mechanism provided in the base, and places the inner hole at a joining position in the arc welding torch and holds the joining auxiliary member in a radially-positioned state; and a pressing mechanism presses the joining auxiliary member in the vicinity of an outer peripheral edge.

A method connects at least two components made of different materials by thermal joining. The two components include a first component made of a material that is suitable for thermal joining and a second component made of a material that cannot be processed using the thermal joining method of the first component. The method includes introducing an auxiliary joining part into the second component forming a form-locking connection and/or a force locking connection. The auxiliary joining part of is made of a material that can be thermally joined to the first component. The first component is thermally joined to the auxiliary joining part in the second component so as to produce a connection between the first component and the second component. The thermal joining is carried out by a beam welding method.

The present invention provides a method for MIG brazing an Al alloy to a steel sheet so as to manufacture a lap joint member that excels in bonding strength with respect to the Al alloy. With the MIG brazing method, a bonding target sheet, specifically, an Al sheet or an Al alloy sheet is bonded to a hot dip Zn-based alloy coated steel sheet (1) whose coating layer contains Al in an amount of 1.0% by mass to 22.0% by mass. A target location of MIG brazing is a region between (i) an intersection (C) of one end of an end surface (6) of the bonding target sheet and the hot dip Zn-based alloy coated steel sheet and (ii) the other end (U) of the end surface of the bonding target sheet.

Present embodiments include a system that includes a welding tool configured to receive a welding wire from a wire feeder, to receive welding power from a power source, and to supply the welding wire to a workpiece during a welding process. The system also includes a mechanical oscillation system configured to mechanically oscillate a structural component toward and away from the workpiece. The structural component is external to the wire feeder and the power source. The system further comprises control circuitry configured to control the welding power based on feedback relating to the welding process.