A weldment includes a first component, a second component, and a weld joint coupling the first and second components together. The weld joint forms a heat affected zone in the first component and creates residual tensile stress in the first component. The first and second components cooperate to define a pocket configured to position a highest magnitude of the residual tensile stress in the first component in a location that is outside of the heat affected zone of the first component.

A method for producing a component structure of two components includes subjecting the components to beam energy for melting in a contact region. A variation of beam current is set to melt the components in the contact region over a defined component depth less than the perpendicular distance between sides of the contact region. A defined beam current pulse is periodically imparted to the variation of the beam current, to melt the components at least approximately over the entire perpendicular distance between the sides of the contact region and to produce in the region of the second side weld regions of a weld root of the weld connecting the components projecting from the contact region and form a pattern which representative of a weld quality. Between the weld regions there is no melting of the components in the region between the defined component depth and the second side.

A method for producing a piston for an internal combustion engine may include the steps of: producing a piston main body from a first blank via a deformation process; producing a piston ring part from a second blank via at least one of a deformation process and a casting process; pre-machining the first blank and the second blank, and finish machining a welding surface of the first blank and a welding surface of the second blank; connecting the pre-machined first blank and the pre-machined second blank via a welding process to form a piston body; and performing at least one of a secondary machining and a finish machining of the piston body to produce the piston.

A manufacturing method is used for an outer joint member of a constant velocity universal joint. The outer joint member includes a cup section having track grooves formed in its inner periphery, which are engageable with torque transmitting elements, and a shaft section formed at a bottom portion of the cup section. The manufacturing method includes welding the cup and shaft members by irradiating a beam to joining end portions of the cup and shaft members, causing an outer surface including the welded portion to be formed into a flat smooth surface by removal processing, irradiating ultrasonic waves to the flat smooth surface with one probe at an incident angle which prevents total reflection in a circumferential angle beam flaw detection method, and setting a focal point of the ultrasonic waves to positions from a surface to an inside of the welded portion, to thereby perform inspection.

A tubular member includes a tube body, a tube end, an exterior surface, an interior surface, a nominal wall thickness, a longitudinal axis, a welded seam, and a patch of material. The welded seam forms an arcuate portion of the interior surface, and the patch covers a portion of the interior surface that includes a portion of the welded seam, extending from the tube end to an axially spaced first location. The resulting interior surface from the tube end to the axially spaced first location has a uniform inside diameter.

A vehicle spindle and a method of attaching the spindle to a portion of an axle half shaft housing. The spindle has an inner surface, an outer surface, one or more bearing journals on the outer surface of the spindle and a radially protruding portion circumferentially extending from at least a portion of the outer surface of an axially inboard end portion of the spindle. Prior to attaching the spindle to the axle half shaft housing, the one or more bearing journals are ground, a clocking angle for the radially protruding portion of the spindle is determined and the spindle is aligned to the determined clocking angle. Once the spindle is aligned to the determined clocking angle, the axially inboard end portion of the spindle is attached to an axially outboard end portion of the axle half shaft housing using one or more welds.

This application describes a manufactured component and method for forming the component. The component comprises: a plurality of parts (212, 214) joined together by a straight line joint (216) and a multi-faceted joint (218). The plurality of parts define a cavity (236) having an internal surface (226) and an external (222) surface. The straight line joint extends through a wall of the component along a straight line between the external surface the internal surface; and, the multi-faceted joint includes an external joint line extending from an external surface to meet an internal joint line which extends from an internal surface, the external and internal joint lines being at an angle to one another. The internal joint line and the straight line joint are aligned with one another such that a straight line extending from the straight line joint will coincide with the internal joint.

The present invention provides a modification to the EBW process, which is referred to as a slope-out methodology, the results in the formation of a slope-out portion located generally in that region of the overall weldment located at the end of the ordinary EBW welding process for joining two components. The slope-out portion overlaps with the initial weld of the workpiece for a given distance or length along the weld and effectively eliminates the keyhole and provides a weldment that has minimal to no defects, particularly in the slope-out portion. The slope-out methodology begins by adjusting various parameters related to the electron beam to essentially decay the beam. In general, the focus position of the electron beam is moved from under-focused (focal position in the bulk of the material) to over-focused (focal position ahead of the workpiece surface) as the overlapping weld is made.

A manufacturing method is used for an outer joint member of a constant velocity universal joint. The outer joint member includes a cup section having track grooves formed in an inner periphery of the cup section, which are engageable with torque transmitting elements, and a shaft section formed at a bottom portion of the cup section. The outer joint member is constructed by forming the cup section and the shaft section as separate members, and by welding a cup member forming the cup section and a shaft member forming the shaft section to each other. The manufacturing method at least includes welding the cup member and the shaft member by irradiating a beam to joining end portions of the cup member and the shaft member, and inspecting a welded portion formed in the welding by a plurality of ultrasonic flaw detection methods with one probe.

A drive unit of a fluid-actuated linear drive includes a piston rod, an annular drive piston seated coaxially on the piston rod and a buffer sleeve which is likewise seated coaxially on the piston rod. These components are secured to one another by one and the same common welded joint. Furthermore, a method for the manufacture of such a drive unit and a fluid-actuated linear drive equipped with such a drive unit is proposed.