A welding or cladding apparatus in which one or more energy beam emitters are used to generate a wide beam spot transverse to a welding or cladding path, and one or more wide feeders feed wire to the spot to create a wide welding or cladding puddle.

A welding or cladding apparatus in which one or more energy beam emitters are used to generate a wide beam spot transverse to a welding or cladding path, and one or more wide feeders feed wire to the spot to create a wide welding or cladding puddle.

A laser welding method of the present disclosure includes a first step and a second step. In the first step, a first end of a first workpiece is positioned such that the first end of the first workpiece is overlapped on a second end of a second workpiece to form a corner joint. In the second step, the first end forming the corner joint is irradiated from above with a laser beam. Additionally, the first end is positioned to protrude relative to the second workpiece in the first step.

A laser welding method of the present disclosure includes a first step and a second step. In the first step, a first end of a first workpiece is positioned such that the first end of the first workpiece is overlapped on a second end of a second workpiece to form a corner joint. In the second step, the first end forming the corner joint is irradiated from above with a laser beam. Additionally, the first end is positioned to protrude relative to the second workpiece in the first step.

A hot stamping method for simultaneously forming workpieces includes steps of: performing laser welding to which an aluminum filler wire is applied to a welding site between the two or more sheets of blanks, and hot-stamping the two or more sheets of blanks, which are welded in the step of performing the laser welding.

A hot stamping method for simultaneously forming workpieces includes steps of: performing laser welding to which an aluminum filler wire is applied to a welding site between the two or more sheets of blanks, and hot-stamping the two or more sheets of blanks, which are welded in the step of performing the laser welding.

A method for repairing damage to a fuel pump assembly of a locomotive is provided that includes identifying a void within a fluid cavity of a fuel pump assembly. After identifying the void within the fluid cavity of the fuel pump assembly, the void is cleaned with a cleaning product, and a filler material is inserted within the void. Then the filler material is laser welded to repair the void. After being laser welded, the fluid cavity of the fuel pump assembly is honed.

A method for repairing damage to a fuel pump assembly of a locomotive is provided that includes identifying a void within a fluid cavity of a fuel pump assembly. After identifying the void within the fluid cavity of the fuel pump assembly, the void is cleaned with a cleaning product, and a filler material is inserted within the void. Then the filler material is laser welded to repair the void. After being laser welded, the fluid cavity of the fuel pump assembly is honed.

A method of joining two ferrous alloy component parts. The method includes hot metal casting a portion of a first ferrous alloy component part onto a first joining surface of a low carbon intermediate element; friction fitting a joining surface of a second ferrous alloy component part against a second joining surface of the low carbon intermediate element; and fusion welding with a concentrated energy source the intermediate element to the second ferrous alloy component part. The hot metal casting includes flowing a molten ferrous alloy onto the textured first joining surface, wherein the molten ally encompasses tabs extending from the first joining surface and filling apertures defined in the intermediate element. Then cooling the molten ferrous alloy such that a metallurgical and mechanical bond is formed between the portion of the first ferrous alloy component part and the first joining surface of the low carbon intermediate element.

A method for gas metal arc welding a first component formed of nitrided steel to a second component with reduced porosity in the weld is provided. A welding wire including a core surrounded by a tube is used to weld the components. The material of the core is formed of mild steel including 0.7 to 3.0 wt. % aluminum and 0.7 to 1.5 wt. % titanium. The material of the tube is formed entirely of low carbon steel. During the weld process, the nitrogen from the nitrided steel combines with the aluminum and titanium of the welding wire to form aluminum nitride and titanium nitride, instead of nitrogen bubbles which lead to high porosity. The method can be used to weld components used in automotive applications, for example to weld a ring gear and can of a flexplate, but alternatively could be used for another automotive or non-automotive applications.