Disclosed are methods and structures for joining metallic members. A welding material can be used between two metallic members that comprise different metals. The different metals can normally form brittle intermetallic compounds when welded to one another, and the welding material can inhibit the formation of the brittle intermetallic compounds.

The objective of the present invention is to provide a friction pressure welding method with which the welding temperature can be controlled accurately, the welding temperature can be lowered, and the distribution of the welding temperature at an interface to be welded can be made uniform; and to provide a welded structure obtained by this method. The present invention relates to the friction pressure welding method in which one member is abutted against another member and is made to slide in a state in which a welding pressure substantially perpendicular to the interface to be welded is applied, said friction pressure welding method being characterized in that the maximum sliding speed is no greater than 53 mm/sec, the difference in the temperature increase rate between a center portion and an outer peripheral portion at the interface to be welded is 10 C./sec or less, and the difference between the maximum attained temperature between the center portion and the outer peripheral portion at the interface to be welded is no greater than 50 C.

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.

A method for joining materials using additive friction stir techniques is provided. The method joins a material to a substrate, especially where the material to be joined and the substrate are dissimilar metals. One such method comprises (a) providing a substrate with one or more grooves; (b) rotating and translating an additive friction-stir tool relative to the substrate; (c) feeding a filler material through the additive friction-stir tool; and (d) depositing the filler material into the one or more grooves of the substrate. Translation and rotation of the tool causes heating and plastic deformation of the filler material, which flows into the grooves of the substrate resulting in an interlocking bond between the substrate and filler material. In embodiments, the depositing of the filler material causes deformation of the grooves in the substrate and an interlocking configuration between the grooves of the substrate and the filler material results.

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.

The method comprises applying a spot load to a joint part between a first metal material and a second metal material in a state where sites to form the joint part are superposed on each other. When a total thickness of the first metal material and the second metal material at the joint part before bonding is defined as T.sub.0 mm, the total thickness thereof after bonding is defined as T.sub.1 mm, and T.sub.0/T.sub.1=R is defined as a reduction ratio, the reduction ratio R is 1.4 or more.

Present embodiments include an additive manufacturing tool configured to receive a metallic anchoring material and to supply a plurality of droplets to a part, wherein each droplet of the plurality of droplets comprises the metallic anchoring material and a mechanical oscillation system configured to mechanically oscillate a structural component of the additive manufacturing tool toward and away from the part, wherein the mechanical oscillation system comprises a motor, a cam coupled to the motor, and a piston coupled to the cam, wherein the piston is fixedly attached to the structural component.

Additive friction stir methods for joining materials are provided. The methods comprise providing first and second substrates to be joined; providing a forming plate comprising one or more forming cavities; placing the first and second substrates in communication with the forming plate; placing the first and second substrates in communication with each other; rotating and translating an additive friction-stir tool relative to the substrates; feeding a filler material through the additive friction-stir tool; deforming the filler material and the first and second substrates; and extruding one or more of the filler material and the first and second substrates into one or more of the forming cavities of the forming plate. Interaction of the additive friction-stir tool with the substrates generates heat and plastic deformation at the joint to weld the substrates at the joint. The methods include introduction of reinforcing material at the joint through addition of the filler material.

An end-to-end tubular joint includes first locking pieces cut from the first tube and second locking pieces cut from the second tube, where the cuts have radial cut faces on the axially aligned cuts. The first and second locking pieces are interlocked with lateral extensions of the respective locking pieces bearing against one another and the radial cut surfaces distributed circumferentially around the joint so as to constrain relative movement between the parts. The first locking pieces are welded to the first tube and the second locking pieces are welded to the second tube to form a tube joint. An alternative forms cutouts in the first tube and fits locking pieces into the cutouts that are welded to a second member, such as a second tube or cylinder that fits into the first tube so as to form the tube joint.

A golf club head with a mitered joint for joining components of dissimilar materials is disclosed herein. The golf club head has a body with an internal edge defining a recess, and a face component having an internal edge. The face component is disposed over the recess. The internal edge of the body and the internal edge of the face have an angle ranging from about 10 degrees to about 80 degrees.