A fusion welding system utilizing a radiant energy heat source such as a laser or electron-beam. The system uses a weld or filler wire having a non-round cross-section shape oriented such that the minor axis of the filler wire is aligned to intersect or nearly intersect the weld bead line. The filler wire cross-sectional shape provides enhanced surface interaction with the radiant energy heat source and possesses mechanical properties enabling more precise positioning of the wire relative to the radiant energy heat source and the weld area.

Described herein are compositions for use in the brazing of metal substrates, methods of making and using these compositions are also described herein. Heat exchangers often have a distributor tube whose external surface is provided with cooling fins. The distributor tube is typically a steel tube coated with a metal having good heat conduction, such as aluminum. The cooling fins themselves also generally comprise aluminum because of its good heat conductivity and low weight.

Systems, methods, and apparatus for treating a molten metal are provided. A metal treatment system, comprising: a wire feeding subsystem; and a cored wire; wherein the wire feeding subsystem feeds the cored wire into a metal bath at a controlled wire feed rate, and wherein the metal bath comprises a molten metal; wherein the cored wire comprises: a consumable outer sheath having a tubular cross section; and a core fill material coupled to an inner surface of the outer sheath, wherein the core fill material comprises a refining agent for refining the molten metal; and wherein the refining agent reacts with the molten metal, thereby causing an impurity to be removable from the metal bath.

A solder alloy comprises 38.0-42.0 wt % bismuth (Bi), 0.01-2 wt % of at least one further element chosen from the group of manganese (Mn), antimony (Sb) and copper (Cu), the balance being tin (Sn), and is at least substantially free of nickel (Ni), and further preferably substantially free of silver (Ag). The solder alloy may be combined with a halide-free solder flux to constitute a solder paste, solder bath or solder wire. The solder paste is for instance used for soldering electronic component packages such as quad flat non-leaded (QFN) packages or for soldering surface mount devices (SMD), resulting in low void formation. The solder alloy may also be applied by means of wave-soldering or selective soldering.

A wire based additive manufacturing system includes a base movable in a feed direction. Multiple welding lasers are each spatially fixed as the base moves in the feed direction. Multiple cutting lasers are each spatially fixed as the base moves in the feed direction. Multiple wire feed members each feed an individual wire of a plurality of wires onto the base as the base moves in the feed direction. Each one the multiple welding lasers is energized to fuse parallel adjoining ones of the plurality of wires, and each one of the cutting lasers is energized to cut one of the fused wires to complete one of a plurality of wire layers.

A welding end assembly for welding system utilizing a consumable wire electrode. The wire electrode has a non-round cross-sectional shape. The end assembly features a tip having internal bore closely conforming to the cross-sectional shape of the electrode wire. An interaction is provided between an external surface of the tip and an internal surface of the diffuser which establishes a desired indexed orientation of the electrode wire cross-section relative to the end assembly.

A welding system having a welding gun with a contact tip having an bore extending therethrough and a consumable weld wire. The cross-sectional shape of the bore of the contact tip being is essentially identical to the cross-sectional shape of the weld wire. The bore having an essentially elliptical cross-sectional shape and the weld wire having an essentially elliptical cross-sectional shape.

An elongate tape (10) acts as a vaporizing actuator for impulse metalworking. It has an electrically-insulative base layer (20), an electrically-conductive layer (30), and an electrically-insulative top layer (40). In it, the base layer is characterized by the length of the tape and a first width W1, as measured between a pair of side edges. The conductive layer is characterized by the length of the tape and a second width W2, as measured between a pair of side edges; and the top layer is characterized by the length of the tape and a third width W3, as measured between a pair of side edges. The layers are joined to each other to form the elongate tape with the electrically-conductive layer interposed between the electrically-insulative base and top layers.

The invention relates to a method of forming a coating or of three-dimensional structural elements on substrate surfaces which is/are formed by TiAl. Said coating/Said three-dimensional structural elements is/are manufactured by laser build-up welding. The procedure is followed in the method in accordance with the invention that titanium and aluminum are supplied into the region of influence of at least one laser beam in wire and/or band form in a pure or alloyed form in each case as a single wire or a single band. They are melted by the thermal input and in this respect the materials are mixed with one another. The coating or three-dimensional structural elements are thereby formed with TiAl on the substrate surface.

A wire based additive manufacturing system includes a base movable in a feed direction. Multiple welding lasers are each spatially fixed as the base moves in the feed direction. Multiple cutting lasers are each spatially fixed as the base moves in the feed direction. Multiple wire feed members each feed an individual wire of a plurality of wires onto the base as the base moves in the feed direction. Each one the multiple welding lasers is energized to fuse parallel adjoining ones of the plurality of wires, and each one of the cutting lasers is energized to cut one of the fused wires to complete one of a plurality of wire layers.