Exothermic welding molds, weld-metal containing cartridges for such molds, and methods of use are provided. The mold, cartridges, and methods can provide interaction between the cartridge's disk member with the mold, which allows the housing member to be withdrawn from the mold while leaving the disk member and weld-metal in place. The interaction can be a rotational restraint alone, a vertical restraint alone, or combinations thereof. Alternately, the interaction can be an outward pressure on the housing member and/or disk member, a shear force on the housing member and/or disk member, or combinations thereof. The outward pressure on the housing member and/or disk member can alternately be provided without interaction between the disk member and the mold, but rather by the simple application of an internal pressure to the cartridge. The internal pressure can be applied by squeezing the walls of the cartridge and/or by depressing a pusher member.

A process for welding metallic sections that includes providing first and second metallic sections to be welded together, and wherein the welded rail sections will include a weld fusion zone that further includes a weld terminus at each rail section; providing thermite welding dies for use in welding the metallic sections together; covering the thermite welding dies with an oxide displacing or oxide dissolving flux added locally to the edges of the thermite welding dies that are immediately adjacent to the weld fusion zone and the metallic sections; positioning the thermite welding dies on the metallic sections in the region where the metallic sections are to be joined together; and initiating an exothermic reaction between the thermite welding dies and the metallic sections by introducing molten metal into the region where the metallic sections are to be joined together, wherein the exothermic reaction creates a weld between the metallic sections.

A system and method for joining dissimilar metals. In one embodiment, a method comprises providing a first metal plate, a second metal plate, and an intermediate body that is positioned between the first metal plate and the second metal plate. The first metal plate is then driven into the intermediate body, which causes at least a portion of the intermediate body to collide with the second metal plate. As a result, the material of the intermediate body joins the first metal plate to the second plate. In another embodiment, a method for joining dissimilar metals comprises providing a first metal that is not amenable to welding, a second metal that is joinable to the first metal, and an intermediate body that is not joinable to at least the first metal. The intermediate body may have at least one hole such that the first metal and the second metal are positioned over and on opposite sides of the hole(s). At least a portion of the second metal may then be driven into the hole(s) to be joined to first metal.

An exothermic reaction mold includes a reaction chamber, a weld chamber communicating with the reaction chamber and at least one user configurable port communicating with the weld chamber for receiving cables to be welded.

A method for manufacturing an engine block is disclosed. In embodiments, the method includes forming an expansion hole in a block body of the engine block that encircles an engine block bore at a head face of the engine block. The method also includes placing an insert into the expansion hole, the insert including an insert body. The method further includes placing a reaction material between the insert and the block body. The method yet further includes forming an insert bond layer between the insert and block body using the reaction material. The method still further includes forming an insert bore through the insert body.

A method of pre-placing a reaction material onto a surface of a metal workpiece substrate involves the use of oscillating wire arc welding. The method involves depositing and adhering the reaction material from a consumable electrode rod. In doing so, the reaction material can be deposited at any time before the metal workpiece substrate is ready for joining by reaction metallurgical joining, and the size and shape of the reaction material deposit can be more easily controlled.

A PCD cutter formed by a reactive/exothermic bond formed between the diamond table and the substrate. The bond is formed by applying a small pulse of localized energy to a bonding agent containing exothermic reactive materials which is disposed at the interface of the diamond table and the substrate. The bonding agent may be formed by depositing a plurality of alternating layers of exothermic foils at the interface between the polycrystalline diamond table and the substrate. Additional layers may also be deposited between the polycrystalline diamond table and the plurality of layers of exothermic foils and between the foils and the substrate. One or more refractory layers may also be disposed between the layers of exothermic material and a masking or non-wetting material may be applied to one or more sides of the substrate and diamond table.

A method for manufacturing an engine block is disclosed. In embodiments, the method includes forming an expansion hole in a block body of the engine block that encircles an engine block bore at a head face of the engine block. The method also includes placing an insert into the expansion hole, the insert including an insert body. The method further includes placing a reaction material between the insert and the block body. The method yet further includes forming an insert bond layer between the insert and block body using the reaction material. The method still further includes forming an insert bore through the insert body.

A method of forge welding includes placing at least two components for welding together, adjacent each other and with an exothermic flux mixture placed between the components. The exothermic flux mixture is heated to initiate an exothermic reaction and the faying surfaces of the two components are pressed together. The components being welded may be tubular, in particular pipes. Apparatus for the method of forge welding and exothermic flux mixtures for the method of forge welding are also provided.

A process for welding metallic sections that includes providing first and second metallic sections to be welded together, and wherein the welded rail sections will include a weld fusion zone that further includes a weld terminus at each rail section; providing thermite welding dies for use in welding the metallic sections together; covering the thermite welding dies with an oxide displacing or oxide dissolving flux added locally to the edges of the thermite welding dies that are immediately adjacent to the weld fusion zone and the metallic sections; positioning the thermite welding dies on the metallic sections in the region where the metallic sections are to be joined together; and initiating an exothermic reaction between the thermite welding dies and the metallic sections by introducing molten metal into the region where the metallic sections are to be joined together, wherein the exothermic reaction creates a weld between the metallic sections.