Provided is a joining method that can prevent a plastic flowing material from flowing out from a butt section and that can reduce the thickness and weight of metal members. The joining method is for joining a first metal member and a second metal member by using a rotary tool comprising a stirring pin, and is characterized in that: the stirring pin comprises a flat surface perpendicular to the rotation axis of the rotary tool and comprises a protruding section protruding from the flat face; and in a friction stirring step, the flat surface is brought into contact with the first metal member and the second metal member, and a front end face of the protruding section is inserted deeper than an upper overlapping section to join an upper front butt section and the upper overlapping section.

The present invention makes it possible to weld workpieces to each other efficiently firmly by friction stir welding while reducing labor and man-hours. A friction stir welding method includes a fixing step, a temporary welding step S2, and a main welding step as follows. The fixing step includes fixing the workpieces W1 and W2 to a receiving table by pressing the workpieces W1 and W2 against the receiving table by means of a plurality of spring pins 10 that, are spaced apart from one another. The temporary welding step S2 includes spot-welding the workpieces W1 and W2 to each other by friction stir welding at locations different from positions of the spring pine 10. The main welding step includes line-welding the spot-welded workpieces W1 and W2 to each other by friction stir welding.

A method of bonding two or more metallic components into a single piece. The bonding surfaces of the metallic components are protected from reaction with the environment. A force is applied to the metallic components to push the bonding surfaces together. Simultaneous with applying the force, an electric current is passed through the bonding surfaces to joule heat and weld the bonding surfaces together to form the single piece. The bonding surfaces may be protected by plating with a noble metal, applying a coating, shielding with a noble gas, or placing into a vacuum. A press may be used to apply the force. The force and the electric current may be sufficient to push out metal around the joint of the bonding surfaces, and at least one of the bonding surfaces may be drafted to facilitate pushing out the metal. The electric current may be pulsed to induce electroplasticity.

Provided herein is a rolled composite aerospace product comprising a 2XXX-series core layer and an Al—Cu alloy clad layer coupled to at least one surface of the 2XXX-series core layer, wherein the Al—Cu alloy is an aluminium alloy comprising about 0.06% to 2.8% Cu, and preferably about 0.10% to 1.8% Cu. The rolled composite aerospace product is ideally suitable for structural aerospace parts. Also described herein is a method of manufacturing a rolled composite aerospace product.

A method for making a cold plate includes the steps of positioning a finstock structure in a cavity of a substrate; and applying a cover to the finstock structure and substrate, wherein the applying step comprises ultrasonically additive manufacturing the cover to the substrate and the finstock structure, whereby the cover joins with the substrate and the finstock structure. The resulting cold plate assembly includes a substrate having a cavity, a finstock structure within the cavity, and a cover closing the finstock structure within the cavity, the cover being integrally joined to the substrate and to the finstock structure.

Provided is an energy storage device which includes: an electrode assembly where electrodes are layered to each other; and current collector joined to the layered electrodes in a state where the current collector overlaps with the electrodes. The electrode and the current collector are welded to each other or are joined to each other by ultrasonic bonding at a first joint portion. At least one of the electrode and the current collector includes a wall surface which projects from a periphery of the first joint portion or a region adjacent to the periphery along a stacking direction of the electrode and the current collector, and surrounds the first joint portion. The wall surface is disposed on both sides of the first joint portion in the stacking direction.

Provided is a joining method that can prevent a plastic flowing material from flowing out from a butt section and that can reduce the thickness and weight of metal members. The joining method is for joining a first metal member and a second metal member by using a rotary tool comprising a stirring pin, and is characterized in that: the stirring pin comprises a flat surface perpendicular to the rotation axis of the rotary tool and comprises a protruding section protruding from the flat face; and in a friction stirring step, the flat surface is brought into contact with the first metal member and the second metal member, and a front end face of the protruding section is inserted deeper than an upper overlapping section to join an upper front butt section and the upper overlapping section.

A first layer (11) and a second layer (12) are layered with an intermediate layer (21) therebetween. A clad material (1) is manufactured by heating and bonding the layered body at a temperature, at which the ratio of the mass of a liquid phase generated from the intermediate layer (21) is 5% or more and 35% or less, and by rolling the body. The clad material may comprise the clad material (1) which is a two-layer material formed of the first layer (11) and the second layer (12) as described above, as well as a third layer, a fourth layer, a fifth layer, and the like.

Electrical connection console for a motor vehicle board net comprising a cable 2 with a metallic stranded conductor 4, and an electrical tap electrically and mechanically connected to the stranded conductor 4, characterized in that the tap is formed from a metallic sleeve 10, in that the sleeve 10 is connected to the stranded conductor 4 in a connection region 8 of the stranded conductor 4, and in that the sleeve 10 has a longitudinal extent in a longitudinal axis parallel to a longitudinal axis of the stranded conductor 4, in that the sleeve 10 has a recess 26 whose longitudinal axis runs transversely with respect to the longitudinal axis of the sleeve 10, and in that a contact sleeve 28 is arranged in the recess 26.

A manifold structure and method of forming a structure having at least one enclosed cavity includes using an ultrasonic additive manufacturing (UAM) process to build up a solid component, forming a cavity in the solid component, filling the cavity with a sacrificial material, using a UAM process to build up a finstock layer over the cavity filled with the powder material to enclose the cavity and form the enclosed cavity, and removing the sacrificial material from the enclosed cavity after the finstock layer is ultrasonically welded to the solid component. The sacrificial material has an adequate density to support the UAM process of forming the finstock layer over the cavity and the material may be removed from the enclosed cavity, resulting in an enclosed cavity having smooth surfaces with an optimal fluid flow area therethrough.