The present disclosure generally relates to methods and apparatuses for additive manufacturing using foil-based build materials. Such methods and apparatuses eliminate several drawbacks of conventional powder-based methods, including powder handling, recoater jams, and health risks. In addition, the present disclosure provides methods and apparatuses for compensation of in-process warping of build plates and foil-based build materials.

The present disclosure generally relates to methods and apparatuses for additive manufacturing using foil-based build materials. Such methods and apparatuses eliminate several drawbacks of conventional powder-based methods, including powder handling, recoater jams, and health risks. In addition, the present disclosure provides methods and apparatuses for compensation of in-process warping of build plates and foil-based build materials, in-process monitoring, and closed loop control.

The present disclosure generally relates to methods and apparatuses for additive manufacturing using foil-based build materials. Such methods and apparatuses eliminate several drawbacks of conventional powder-based methods, including powder handling, recoater jams, and health risks. In addition, the present disclosure provides methods and apparatuses for compensation of in-process warping of build plates and foil-based build materials, in-process monitoring, and closed loop control.

Provided is a flux for submerged arc welding that has good welding workability and can reduce the diffusion hydrogen content in a weld metal using either an AC or a DC welding power source. The flux includes Al.sub.2O.sub.3: 15 to 35% by mass; SiO.sub.2: 10 to 30% by mass; MgO: 10 to 25% by mass; F expressed in terms of CaF.sub.2: 10 to 25% by mass; Mn expressed in terms of MnO: 3 to 20% by mass; Na expressed in terms of Na.sub.2O and/or K expressed in terms of K.sub.2O: 0.5 to 4.5% by mass in total; Fe expressed in terms of FeO: 0.5 to 8% by mass; and CaO: 6% by mass or less. A water-soluble SiO.sub.2 in the flux is less than 1% by mass. In addition, the flux has a composition that satisfies the following formula: 0.2[Mg/O]/([Al.sub.2O.sub.3]+[MnO])0.8.

A welding torch assembly includes a mounting plate. A welding torch is mounted to the mounting plate. The welding torch includes an adjustment track fixed to the mounting plate, an adjustment body slidable relative to the adjustment track, a torch body, an electrode holder having a longitudinal axis. An electrode includes an elongated body defining a longitudinal axis. A seating end portion includes a first truncated cone. A working end portion includes a second truncated cone. The elongated body is located between the seating portion and the working portion. A retaining nut secures the electrode in the electrode holder. The electrode retaining nut contacts the angled surface of the seating end portion. A shield gas cup is secured to the torch body that forms a welding arc to melt filler wire.

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

A method of joining workpieces includes locating first ends of two first workpieces in a moveable part coupling portion. The lengths of the first workpieces are measured. Any difference in length between the first workpieces is determined. Two additional workpieces are located adjacent the first ends of the first workpieces based on the determined difference in length. The first workpieces are connected to the second workpieces.

A hybrid article is disclosed including a coating disposed on and circumscribing the lateral surface of a core having a core material. The coating includes about 35% to about 95% of a first metallic material having a first melting point, and about 5% to about 65% of a second metallic material having a second melting point lower than the first melting point. The coating is sinter-bonded to the core. A method for forming the hybrid article is disclosed including disposing the core in a die, introducing a slurry having the metallic materials into a gap between the lateral surface and the die, and sintering the slurry, forming the coating. A method for closing an aperture of an article is disclosed including inserting the hybrid article into the aperture, and brazing the hybrid article to the article, welding the aperture with the hybrid article serving as weld filler, or both.

The disclosed technology generally relates to consumable electrode wires and more particularly to consumable electrode wires having a core-shell structure, where the core comprises aluminum. In one aspect, a welding wire comprises a sheath having a steel composition and a core surrounded by the sheath. The core comprises aluminum (Al) at a concentration between about 3 weight % and about 20 weight % on the basis of the total weight of the welding wire, where Al is in an elemental form or is alloyed with a different metal element. The disclosed technology also relates to welding methods and systems adapted for using the aluminum-comprising electrode wires.

A method for forming an article is disclosed, including laser welding a powder of an HTW alloy to a surface of a substrate along a weld path, forming a weld bead of the HTW alloy. The weld path is propagated along a weld direction, forming a cladding layer of the HTW alloy on the surface. The laser welding includes a laser energy density of at least about 11 kJ/cm.sup.2, and laser welding the powder to the surface includes a welding speed of about 5-20 ipm. The weld path oscillates essentially nonparallel to a reference line, establishing a cladding width wider than the weld bead width. The weld bead contacts itself along each oscillation such that the cladding layer is continuous and essentially free of cracks. A turbine bucket is disclosed including a squealer tip having the cladding layer with a cladding layer thickness of at least about 0.2 inches.