A method of joining and sealing a vanadium based membrane to a metallic connection section comprising: mounting a section of a vanadium based membrane on a connector formation of a connection section, the connection section being formed of a different metal to the vanadium based membrane, the connector formation providing a recess into which a section of the vanadium based membrane is seated and a connection interface in which the end face of the vanadium based membrane is proximate to or substantially abuts an adjoining face of the connector formation; mounting and operating a chiller arrangement in thermal contact with vanadium based membrane proximate the connection interface; heating a filler metal on the connection section to at least the liquidus temperature of the filler metal using a laser beam directed onto the filler metal located on the connection section and having a beam edge positioned at an offset location spaced apart from the connection interface a distance that attenuates direct heating of the vanadium based membrane by the laser beam, and on the connection section, such that the filler metal can flow over the connection interface from the offset location onto the vanadium based membrane; and cooling the filler metal to form a bridging section of filler metal between the vanadium based membrane and connection section over the connection interface.

Presented are intelligent non-autogenous metalworking systems and control logic for automated wire-to-beam alignment, methods for making/using such systems, and robot-borne laser welding/brazing heads with closed-loop control for real-time wire alignment. A method for controlling operation of a non-autogenous workpiece processing system includes a system controller receiving sensor signals from a position sensor indicative of a location of filler wire discharged into a joint region by a wire feeder. Using the received sensor signals, the controller determines a displacement between the wire location and a location of a beam emitted onto the joint region by a beam emitter. If the wire displacement is greater than a threshold wire displacement value, the controller responsively determines a corrective force calculated to reduce wire displacement to below the threshold wire displacement value. The controller then commands the actuator to pivot the processing head to thereby apply the corrective force to the discharging filler wire.

Presented are intelligent non-autogenous metalworking systems and control logic for automated wire-to-beam alignment, methods for making/using such systems, and robot-borne laser welding/brazing heads with closed-loop control for real-time wire alignment. A method for controlling operation of a non-autogenous workpiece processing system includes a system controller receiving sensor signals from a position sensor indicative of a location of filler wire discharged into a joint region by a wire feeder. Using the received sensor signals, the controller determines a displacement between the wire location and a location of a beam emitted onto the joint region by a beam emitter. If the wire displacement is greater than a threshold wire displacement value, the controller responsively determines a corrective force calculated to reduce wire displacement to below the threshold wire displacement value. The controller then commands the actuator to pivot the processing head to thereby apply the corrective force to the discharging filler wire.

A method for laser beam welding of one or more steel sheets made of press-hardenable manganese-boron steel is disclosed. At least one of the steel sheets has a coating of aluminium. The laser beam welding takes place by feeding an additional wire into a melt bath generated by of a laser beam. The additional wire contains at least one austenite-stabilising alloy element. The weld seam after hot forming (press hardening) has a strength that is comparable to the base material. The laser beam is put into oscillation such that it oscillates transverse to the welding direction, wherein the oscillation frequency of the laser beam is at least 200 Hz, preferably at least 500 Hz. The method dispenses with removing the aluminum coating at the edge of the sheet-metal edges to be welded.

A method for laser beam welding of one or more steel sheets made of press-hardenable manganese-boron steel is disclosed. At least one of the steel sheets has a coating of aluminium. The laser beam welding takes place by feeding an additional wire into a melt bath generated by of a laser beam. The additional wire contains at least one austenite-stabilising alloy element. The weld seam after hot forming (press hardening) has a strength that is comparable to the base material. The laser beam is put into oscillation such that it oscillates transverse to the welding direction, wherein the oscillation frequency of the laser beam is at least 200 Hz, preferably at least 500 Hz. The method dispenses with removing the aluminum coating at the edge of the sheet-metal edges to be welded.

Welding methods and welded joints for improving corrosion resistance of the joint between a plurality of high-strength aluminum alloy structural members are described herein. An example method can include applying a first weld at a junction between the plurality of high-strength aluminum alloy structural members using a first filler metal, and applying a second weld on at least a portion of a toe of the first weld using a second filler metal. The second weld can be applied using a fusion welding process (e.g., an arc welding process or a high energy beam welding process). Additionally, the secondary weld can alter a secondary phase of the first weld.

Welding methods and welded joints for improving corrosion resistance of the joint between a plurality of high-strength aluminum alloy structural members are described herein. An example method can include applying a first weld at a junction between the plurality of high-strength aluminum alloy structural members using a first filler metal, and applying a second weld on at least a portion of a toe of the first weld using a second filler metal. The second weld can be applied using a fusion welding process (e.g., an arc welding process or a high energy beam welding process). Additionally, the secondary weld can alter a secondary phase of the first weld.

A first abutting surface, a first welding surface, a first facing surface are formed in a differential case. A second abutting surface, a second welding surface, and a second facing surface are formed in a differential ring gear. In an installing step, the first abutting surface and the second abutting surface are inserted, positions of the differential case and the differential ring gear are determined in an axial direction, a separation portion that spaces the first welding surface and the second welding surface away from each other and that has a non-linear portion is formed, and a void is formed between the first facing surface and the second facing surface. In a welding step, a laser is irradiated to the separation portion and the first welding surface and the second welding surface are welded.

A system includes a laser welder and a filler wire feed. The laser welder is configured to weld a workpiece to at least one additional workpiece to form a welded assembly. Each of the workpieces is formed from a steel material and comprises an aluminum based coating thereon. The filler wire feed is configured to feed a filler wire to an interface between the workpieces when the workpieces are being welded to each other to form the welded assembly. The filler wire comprises a composition that includes nickel and chromium. The filler wire is configured to bind with aluminum in the aluminum based coating so as to minimize formation of brittle intermetallics due to mixing of the aluminum in the aluminum based coating with the iron/steel material in the weld joint.

A system includes a laser welder and a filler wire feed. The laser welder is configured to weld a workpiece to at least one additional workpiece to form a welded assembly. Each of the workpieces is formed from a steel material and comprises an aluminum based coating thereon. The filler wire feed is configured to feed a filler wire to an interface between the workpieces when the workpieces are being welded to each other to form the welded assembly. The filler wire comprises a composition that includes nickel and chromium. The filler wire is configured to bind with aluminum in the aluminum based coating so as to minimize formation of brittle intermetallics due to mixing of the aluminum in the aluminum based coating with the iron/steel material in the weld joint.