Novel High-Entropy Alloy (HEA) compositions are particularly suited to welding applications. The mixtures contain at least the elements nickel, manganese, cobalt, chromium, vanadium, molybdenum, and iron. The % weight of the constituents varies in accordance with the detailed description contained herein, with tolerances in the range of ±4% for major alloying elements and ±1% for minor alloying elements. The mixture may also contain a small amount of Aluminum, Titanium, and Boron with a tolerance in the range of +/−1% or, more preferably, +/−0.5% In accordance with the invention, the compositions above may be integrated into HEA welding products using cored wire and welding electrode manufacturing techniques, preferably starting with vacuum melted rolled alloys. One manufacturing process uses the compositions as an alloyed strip formed around the appropriate ground/crushed alloys to make commercially viable fabricated welding products.

According to an embodiment, a method for manufacturing a joined metal member includes: disposing a first metal member inside a mold of an injection molding apparatus, the first metal member being made of a first metal material, unevenness being formed over a surface of the first metal member, and an oxide film being formed so as to cover the unevenness; and injecting a second metal material into the mold, and thereby molding a second metal member and joining the second metal member to the first metal member, the second metal material being, when it is injected into the mold, in a semi-molten state, or in a molten state in which a difference between a temperature of the second metal material and a liquidus temperature thereof is smaller than or equal to 30° C.

A method of forming a ferrous metal case-hardened layer using additive manufacturing. The method includes delivering, by a material delivery device, a filler material to a surface of a substrate. The substrate includes a first ferrous metal. The filler material includes a second ferrous metal and a carbon-based material. The method also includes directing, by an energy delivery device, an energy toward a volume of the filler material to join at least some of the filler material to the substrate to form a component.

The present disclosure is directed to a multi-segment device, such as an intravascular guide wire. The multi-segment device includes an elongate first portion comprising a first metallic material, an elongate second portion comprising a different metallic material, the first and second elongate portions being directly joined together end to end by a solid-state weld, and a heat affected zone surrounding an interface of the weld where the first and second portions are joined together, wherein the heat affected zone has an average thickness of less than about 0.20 mm.

An additive manufacturing system includes an electrode head comprising an array of electrodes for depositing material to form a three-dimensional part. The array includes a first plurality of electrodes formed from a first metallic material having a first ductility and a first hardness, and a second plurality of electrodes formed from a second metallic material having a second ductility and a second hardness, wherein the first ductility is greater than the second ductility and the second hardness is greater than the first hardness. A power source provides electrical power for establishing a welding arc for each electrode. A drive roll system drives each electrode. A controller is connected to the power source to control operations of the additive manufacturing system to form an interior portion of the part using the first plurality of electrodes, and control the operations of the additive manufacturing system to form an exterior portion of the part using the second plurality of electrodes, such that ductility of the interior portion of the part is greater than ductility of the exterior portion of the part.

The disclosure describes assemblies, systems, and techniques for reinforcing complex geometries of pressure vessels using a pre-sintered preform (PSP) braze material that includes a low-melt powder and a high-melt powder. An example technique includes positioning a PSP reinforcement on a surface of a substrate. The technique includes heating the PSP reinforcement to soften or melt at least one constituent metal or alloy of the low-melt powder. During heating, the PSP reinforcement is configured to conform to a contour of the surface of the substrate. The technique also includes cooling the PSP reinforcement to define a reinforced component.

An electrical connector includes a first layer formed of a copper based material and a second layer formed of an iron-nickel alloy. The second layer has a thickness of 8% to 30% of the thickness of the electrical connector. The electrical connector also includes a third layer which is formed of a solder alloy that consists essentially of 17% to 28% indium by weight, 12% to 20% zinc by weight, 1% to 6% silver by weight, 1% to 3% copper by weight, and a remaining weight of the solder alloy that is tin.

The present disclosure is directed to a multi-segment device comprising an elongate first portion comprising a first metallic material, an elongate second portion comprising a different metallic material, the first and second elongate portions being directly joined together end to end, a heat affected zone surrounding an interface of the elongate first portion and the elongate second portion, a shapeable distal end formed from at least a portion of the elongate second portion, a coil disposed about a portion of the elongate second portion.

The disclosure describes assemblies, systems, and techniques for reinforcing complex geometries of pressure vessels using a pre-sintered preform (PSP) braze material that includes a low-melt powder and a high-melt powder. An example component includes a substrate comprising at least a portion of a pressure vessel. The substrate defines a contoured exterior surface of the pressure vessel. The component includes a pre-sintered preform (PSP) reinforcement formed on the surface of the substrate by brazing, wherein the PSP reinforcement comprises a low-melt powder and a high-melt powder.

The present invention provides dissimilar material solid phase bonding with which a robust bonded portion of metal materials having different compositions can be formed efficiently. The present invention also provides a dissimilar material solid phase bonded structure having a dissimilar material solid phase bonded portion in which metal materials having different compositions have been bonded together robustly. In the dissimilar material solid phase bonding method according to the present invention, one member is brought into contact with another member to form an interface to be bonded, and newly formed surfaces of the one member and the other member are formed at the interface to be bonded, by means of the application of a bonding load, characterized in that: the one member and the other member have different compositions; the temperature at which the one member and the other member have substantially the same strength is defined as a bonding temperature; and the bonding load at which strength is applied substantially perpendicular to the interface to be bonded is set.