A mobile hardbanding system that uses PTA welding to perform hardbanding on drill string sections at the well site. The inventive system allows alternate use of PTA and MIG welding. Both a PTA torch and a MIG torch are provided. Changing from one type of welding to the other is simplified by including separate electrical, gas, and cooling conduits for each torch. The torch not in use is parked in the welding compartment near the weld box. The powder hopper for the PTA welding assembly may be mounted on a swivel arm so that it can be moved out of the way when the MIG torch is in use.

A method for repairing a cast component made of a magnesium-based material is disclosed. The method comprises receiving the cast component made of the magnesium-based material and adding repair material to the cast component using cold metal transfer (CMT) welding.

A mobile hardbanding system that uses PTA welding to perform hardbanding on drill string sections at the well site. The inventive system allows alternate use of PTA and MIG welding. Both a PTA torch and a MIG torch are provided. Changing from one type of welding to the other is simplified by including separate electrical, gas, and cooling conduits for each torch. The torch not in use is parked in the welding compartment near the weld box. The powder hopper for the PTA welding assembly may be mounted on a swivel arm so that it can be moved out of the way when the MIG torch is in use.

A method of manufacturing a component is disclosed. The method includes depositing a material on a removable form structure having geometry corresponding to an internal space of the component. The material is deposited on the removable form structure by an additive manufacturing technique. The method includes removing the removable form structure to obtain a pre-machined component, and then machining the pre-machined component to manufacture the component having the internal space.

A drill-string liner element includes at least one hardbanding layer. The hardbanding layer includes one or more strands of filler metal, each having a width between 1 and 5 millimeters and deposited in adjacent manner to form a substantially continuous layer over a zone of the element. The hardness in the thickness of the layer varies by less than 10 HRC over the zone.

A method of welding a component and a treated component are provided. The method comprises an initial heat-treating of the component comprising a substrate. The method further comprises removing a portion of the substrate to form a treatment region comprising an exposed surface. The method further comprises buttering the exposed surface with a first filler additive to form a weld metal adjacent to the fusion line comprising an easy-to-weld alloy. The method further comprises welding the component with the easy-to-weld alloy and a second filler additive. The first filler additive comprises a sufficient amount of each of Co, Cr, Mo, Fe, Al, Ti, Mn, C and Ni to form the easy-to-weld alloy, when welded with the hard-to-weld base alloy.

A thin wall spinformed metallic tank shell includes a first region with a first thickness and at least one second region with a second thickness greater than the first thickness including structural features formed by an additive manufacturing process, where the features are added outside and inside of the metallic tank shell and can include: polar bosses added to one or both external polar regions of a spherical section of the tank; mounting tabs on a circumferential skirt of the tank; mounting rings containing threaded holes attached to the interior or exterior surface of the tank; mounting trunnions attached to the external surface of the tank; propellant management devices attached to the interior surface of the tank; structural reinforcement vanes and ribs attached to the inside surface of the tank; and brackets and/or shelves attached to the inside surface of the tank.

A method of applying non-magnetic semi-helical hardbanding to a non-magnetic drill collar used in well-drilling operations is disclosed herein. The method involves applying semi-helical bands using Plasma Transferred Arc (PTA), laser hardfacing, or a similar thermal-welding technique. At least one non-magnetic alloy is used to form a set of evenly spaced single blades around the circumference of the drill collar. The blades are arranged such that no single blade extends around the full circumference of the collar.

A method of manufacturing gear teeth by additive manufacturing. Each tooth (20) is constructed from a predetermined number of layers (30, 31, 32) of material (e.g. steel) with each layer being formed by a predetermined number of rows (33-41) of material preferably applied by a welding head (13) or equivalent apparatus.

A method of forming a thick wall section on a specific region of a thin wall spinformed metallic tank shell includes forming a thin wall metallic tank shell blank by spinforming a metal sheet over a mandrel and removing the tank shell blank from the mandrel. The method further includes mounting the blank in an additive manufacturing system and adding metallic structural features to the tank shell according to a 3D model stored in memory in the additive manufacturing system.