A bus bar and a method of manufacturing the same may include a first metal portion made of a first metal material; and a second metal portion made of a second metal material different than the first metal portion. The first metal portion and the second metal portion are coupled by a rotation friction welding (RFW).

A liquid cooling head manufacturing method includes the following steps. First, a liquid channel main body is provided. Then, a heat dissipation bottom plate and a heat sink are disposed in different recessed indentations in the liquid channel main body. The heat dissipation bottom plate and the heat sink are welded in the liquid channel main body and a cover plate is sealed on the liquid channel main body.

A terminal connecting method includes setting a conductor having a plurality of strands on an upper surface of a bottom portion of an electric wire crimping part of a terminal, caulking the conductor in a manner to cover the conductor, thereby crimping the conductor by a caulking portion extended from the bottom portion, and welding the plurality of strands together in a strands exposed portion of the conductor exposed from tip end edges of the caulking portion by friction between the plurality of strands and a friction tool, after caulking and crimping.

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.

A method of diffusion bonding metal or metal alloy containing workpieces, comprises (a) coating the bonding surfaces of the metal or metal alloy containing workpieces with a layer of a coating material, (b) abrading the coated bonding surfaces to remove surface oxide, the coating material being in liquid form, (c) removing excess coating material or excess abraded metal or metal alloy containing workpiece material from the coated bonding surfaces, and (d) diffusion bonding the coated bonding surfaces of the metal or metal alloy containing workpieces together. The coating material is operable to form a stable barrier on the bonding surfaces of the metal or metal alloy containing workpieces under ambient conditions, and evaporates from the bonding surfaces under diffusion bonding conditions. There is also a bonded workpiece formed using the method of diffusion bonding metal or metal alloy containing workpieces.

According to an embodiment, a method for manufacturing a thin plate comprises placing a copper piece on a side of an aluminum piece, forming a heterogeneous metal joined body by performing friction welding on the side of the aluminum piece and a side of the copper piece to thereby form a spread layer of the aluminum piece on the side of the aluminum piece, and a spread layer of the copper piece on the side of the copper piece, the respective spread layers of the aluminum piece and the copper piece being mixed into a mixed layer that is then cured, and forming the thin plate by roll-milling the heterogeneous metal joined body.

Shear assisted extrusion processes (ShAPE) for forming Metal-NCCF extrusions are provided. The processes can include: using a die tool, applying a rotational shearing force and an axial extrusion force to a feedstock material comprising a metal and NCCF (NanoCrystalline Carbon Films); and extruding a mixture comprising the metal and NCCF through an opening in the die tool to form the Metal-NCCF extrusion. ShAPE feedstock materials are provided that can include a metal and NCCF. Conductive solid material mixtures are provided that can include a metal and a NCCF. Portions of the metals and NCCF of the material mixtures can have an isotropic crystallographic orientation. Assemblies relying in part on conductivity can include: a conductive solid material mixture that includes: a metal; and a NCCF.

A battery module includes a plurality of battery cells each having a terminal, and a lead plate having a lead part each of which is joined to the terminal of each of the battery cells to electrically connect the battery cells to each other. The lead part includes an aluminum thin plate having aluminum purity higher than or equal to 99.0%. Surface roughness Ra of a joining surface of the lead part to the terminal is less than or equal to 10 μm. The lead part is electrically connected to the terminal by solid-phase bonding.

The present invention includes: a preparation process configured to provide a first metal member including an end portion with a vertical face, and a second metal member including an end portion with an inclined face, a higher melting point and a smaller plate thickness than the first metal member; a butting process configured to butt the end portions of the first metal member and the second metal member against each other and form a butted portion with a V-shaped gap; and a joining process configured to join the first metal member and the second metal member together by inserting the rotating rotary tool from only a front face of the first metal member and relatively moving the rotary tool along the butted portion while only the stirring pin is in contact with at least the first metal member.

A friction stir welding equipment according to an embodiment includes a spindle unit, a holder, and a moving part; the spindle unit is capable of rotating a tool; the holder is connectable to the tool via a radial bearing and is capable of holding at least one of a side surface of a processing member or a rim of an upper surface of the processing member; and the moving part is capable of changing relative positions of the tool and the holder with respect to the processing member.