A method for forming an impact weld used in an additive manufacturing process. The method includes providing a wire having a powder filler metal core located within a sheath. The wire is then inserted within a conduit having an opening. Further, the method includes providing at least one energy pulse that interacts with the sheath to pinch off at least one segment of the wire, wherein the energy pulse causes propulsion of the segment toward a substrate with sufficient velocity to form an impact weld for welding the metal core to the substrate. In particular, the energy pulse is an electromagnetic pulse, a laser energy pulse or a high electric current pulse.

A method for forming an impact weld used in an additive manufacturing process. The method includes providing a wire having a powder filler metal core located within a sheath. The wire is then inserted within a conduit having an opening. Further, the method includes providing at least one energy pulse that interacts with the sheath to pinch off at least one segment of the wire, wherein the energy pulse causes propulsion of the segment toward a substrate with sufficient velocity to form an impact weld for welding the metal core to the substrate. In particular, the energy pulse is an electromagnetic pulse, a laser energy pulse or a high electric current pulse.

A method of impact welding a flyer to a hollow component is provided. The method includes providing the component made of a first material and including a cavity where a weld site is disposed on a first side of the component. An incompressible material is packed against a second side of the component opposite the first side facing the cavity. A flyer made of a second material is positioned onto the weld site. The flyer is then impact welded to the component. The incompressible material prevents the deformation of the component during the impact welding. A method of impact welding a cover plate to a component is provided as well as a support system for welding repair of hollow components.

A method of impact welding a flyer to a hollow component is provided. The method includes providing the component made of a first material and including a cavity where a weld site is disposed on a first side of the component. An incompressible material is packed against a second side of the component opposite the first side facing the cavity. A flyer made of a second material is positioned onto the weld site. The flyer is then impact welded to the component. The incompressible material prevents the deformation of the component during the impact welding. A method of impact welding a cover plate to a component is provided as well as a support system for welding repair of hollow components.

A pulsed joining tool includes a tool body that defines a cavity that receives an inner tubular member and an outer tubular member and a pulse joining cartridge. The tubular members are nested together with the cartridge being disposed around the outer tubular member. The cartridge includes a conductor, such as a wire or foil, that extends around the outer tubular member and is insulated to separate a supply segment from a return segment. A source of stored electrical energy is discharged through the conductor to join the tubular members with an electromagnetic force pulse.

A pulsed joining tool includes a tool body that defines a cavity that receives an inner tubular member and an outer tubular member and a pulse joining cartridge. The tubular members are nested together with the cartridge being disposed around the outer tubular member. The cartridge includes a conductor, such as a wire or foil, that extends around the outer tubular member and is insulated to separate a supply segment from a return segment. A source of stored electrical energy is discharged through the conductor to join the tubular members with an electromagnetic force pulse.

The invention relates to a welding head for magnetic pulse welding of hollow thin-walled profile to an inner member having a complementary outer form to said hollow thin-walled profile. The weld head comprises two movable weld head halves (10a,10b) forming said weld head wherein each half has at least one individual induction coil (12a,12b) connected to a power source independently from the other weld head half, with coils wound in a kidney-shape. The work piece is clamped between shapers (15a,15b) integrated with each half. With this weld head could for example work pieces such as tubular thin-walled profiles be welded, even if they are integrated in a closed tubular design, as the weld head could be closed quickly over the welding position and opened for release of the work piece without experiencing arching in clamping area.

The invention relates to a welding head for magnetic pulse welding of hollow thin-walled profile to an inner member having a complementary outer form to said hollow thin-walled profile. The weld head comprises two movable weld head halves (10a,10b) forming said weld head wherein each half has at least one individual induction coil (12a,12b) connected to a power source independently from the other weld head half, with coils wound in a kidney-shape. The work piece is clamped between shapers (15a,15b) integrated with each half. With this weld head could for example work pieces such as tubular thin-walled profiles be welded, even if they are integrated in a closed tubular design, as the weld head could be closed quickly over the welding position and opened for release of the work piece without experiencing arching in clamping area.

Joining methods and corresponding structures are disclosed. In some instances, a method for joining two or more components may include generating a shockwave in a first component to form a jet of a material of the first component directed towards a second component. The jet may penetrate the second component to connect the first component with the second component. Articles of pre-joined and joined components are also described.

An electrode and a device for resistance spot welding are capable of preventing an occurrence of a surface spatter by using magnetism. The electrode may include a shank and a welding tip mounted to an end of the shank. A magnetic unit is installed on an outer peripheral surface of the shank to form a magnetic field and to form a Lorentz force in a direction of rotation along a circumferential direction of the shank by the magnetic field and a current flowing through the shank.