An additive manufacturing system includes an additive manufacturing tool configured to receive a plurality of metallic anchoring materials and to supply a plurality of droplets to a part, and a controller configured to independently control the composition, formation, and application of each droplet to the plurality of droplets to the part. 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 of the plurality of metallic anchoring materials.

Solid-state joining of preformed features, such as bosses, flanges, gaskets, centralizers and other features to substrates or cast parts by a solid-state additive manufacturing process is disclosed. Joining can be between same or different materials using same, similar or dissimilar filler material than the materials of the feature and the part that need to be joined.

An additive manufacturing system includes an additive manufacturing tool configured to receive a plurality of metallic anchoring materials and to supply a plurality of droplets to a part, and a controller configured to independently control the composition, formation, and application of each droplet to the plurality of droplets to the part. 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 of the plurality of metallic anchoring materials.

A method of inserting a rivet into a workpiece comprises moving the rivet and workpiece relative to one another, along a longitudinal axis of the rivet, so as to drive the rivet into the workpiece. The rivet is rotated about its longitudinal axis, relative to the workpiece, for at least part of the time during which it is in contact with the workpiece. The speed of said rotation, or the speed of movement along the longitudinal axis of the rivet, is altered at least once before driving of the rivet into the workpiece is complete. One axial end of the rivet has a tip for piercing the workpiece, and the rivet has a substantially cylindrical shank extending longitudinally from the tip. The shank has one or more surface irregularities.

A friction stir processing (FSP) tool includes a working material. The working material has a matrix phase and a particulate phase. The matrix phase includes tungsten and an alloy material. The particulate phase is located within the matrix phase, and the particulate phase has an indentation hardness less than 45 GPa.

An example method for joining metals is described herein. The method can include forming an intermediate joint between a light metal member and a metal insert, where the intermediate joint is formed using a solid state welding process. The method can also include forming a primary joint between the light metal member and a high strength steel member, where the primary joint is formed using a welding process that produces coalescence at a temperature above the melting point of the light metal member and/or the high-strength steel member.

A negative electrode for an electrochemical cell of a lithium metal battery may be manufactured by welding together a lithium metal layer and a metallic current collector layer. The lithium metal layer and the current collector layer may be arranged adjacent one another and in an at least partially lapped configuration such that faying surfaces of the layers confront one another and establish a faying interface therebetween at a weld site. A laser beam may be directed at an outer surface of the current collector layer at the weld site to melt a portion of the lithium metal layer adjacent the faying surface of the current collector layer and produce a lithium metal molten weld pool. The laser beam may be terminated to solidify the molten weld pool into a solid weld joint that physically bonds the lithium metal layer and the current collector layer together at the weld site.

Methods of fabricating reduced weight components for apparatuses include obtaining a component including a relatively lightweight material; placing at least one stabilizing structure on the component; sequentially applying a plurality of applied layers on the component and the stabilizing structure by applying the relatively lightweight material over the component and applying over the relatively lightweight material a plurality of layers having gradually progressively higher proportions of the relatively heavyweight material than preceding ones of the plurality of layers closer to the component, with an outer layer of the plurality of applied layers including the relatively heavyweight material; diffusion bonding the plurality of applied layers by consolidation of the plurality of applied layers; and cutting component features in the plurality of applied layers.

A method of inserting a rivet (2) into a workpiece (42, 44, 46) comprises moving the rivet (2) and workpiece (42, 44, 46) relative to one another, along a longitudinal axis of the rivet, so as to drive the rivet into the workpiece. The rivet is rotated about its longitudinal axis, relative to the workpiece, for at least part of the time during which it is in contact with the workpiece. The speed of said rotation, or the speed of movement along the longitudinal axis of the rivet, is altered at least once before driving of the rivet into the workpiece is complete.

A joining structure includes: a first tube made of a first metal or alloy; a second tube made of a second metal or alloy different from the first metal or alloy; a coupling member having a cylindrical shape to provide therein a passage into which the first and second tubes are insertable, and having an opening on a side face thereof to penetrate into the passage; and a brazing material injected into the passage through the opening with an end face of the first tube and an end face of the second tube abutting on each other in the passage to braze the first tube, the second tube, and the coupling member. The second metal or alloy is more easily oxidizable than the first metal or alloy during brazing. An abutting position between the first and second tubes is deviated from the opening toward the second tube.