A method of manufacturing metal matrix composite (MMC) parts, including the steps of applying a metallic sheath around a bundle of MMC laminates, heating the bundle of MMC laminates in the metallic sheath at a curing or fusing temperature to consolidate the bundle of MMC laminates into a single cured or fused part, and then cooling the cured or fused part. The bundle of MMC laminates may be formed by removing surface contamination from the dry reinforcement fibers, creating a plurality of individual MMC laminates by plating dry reinforcement fibers with electroless nickel, and/or electrodeposited nickel or cobalt, and stacking each of the plurality of individual MMC laminates into a bundle. Autocatalytic and/or electroplating may be used as the primary means to incorporate fiber reinforcement into the metal matrix composite by covering and bonding fiber reinforcement into MMC laminates/plies and/or 3-D woven parts.

A brazing process using Nickel(Ni)-Carbon as graphite(Cg) alloys, Ni-Cg-Molybdenum(Mo) alloys, and Ni-Cobalt(Co)-Cg-Mo alloys for brazing together ceramics, ceramics to metals, metals to metals. Semiconductor processing equipment made with the use of Ni-Cg alloys, such as heaters and chucks. Semiconductor processing equipment components and industrial equipment components using a highly wear resistant surface layer, such as sapphire, joined to a substrate such as a ceramic, with a Ni-Cg alloy braze.

A brazing process using Nickel(Ni)-Carbon as graphite(Cg) alloys, Ni-Cg-Molybdenum(Mo) alloys, and Ni-Cobalt(Co)-Cg-Mo alloys for brazing together ceramics, ceramics to metals, metals to metals. Semiconductor processing equipment made with the use of Ni-Cg alloys, such as heaters and chucks. Semiconductor processing equipment components and industrial equipment components using a highly wear resistant surface layer, such as sapphire, joined to a substrate such as a ceramic, with a Ni-Cg alloy braze.

Dual alloy turbine rotors and methods for manufacturing the same are provided. The dual alloy turbine rotor comprises an assembled blade ring and a hub bonded to the assembled blade ring. The assembled blade ring comprises a first alloy selected from the group consisting of a single crystal alloy, a directionally solidified alloy, or an equi-axed alloy. The hub comprises a second alloy. The method comprises positioning a hub within a blade ring to define an interface between the hub and the blade ring. The interface is a non-contacting interface or a contacting interface. The interface is enclosed by a pair of diaphragms. The interface is vacuum sealed. The blade ring is bonded to the hub after the vacuum sealing step.

Dual alloy turbine rotors and methods for manufacturing the same are provided. The dual alloy turbine rotor comprises an assembled blade ring and a hub bonded to the assembled blade ring. The assembled blade ring comprises a first alloy selected from the group consisting of a single crystal alloy, a directionally solidified alloy, or an equi-axed alloy. The hub comprises a second alloy. The method comprises positioning a hub within a blade ring to define an interface between the hub and the blade ring. The interface is a non-contacting interface or a contacting interface. The interface is enclosed by a pair of diaphragms. The interface is vacuum sealed. The blade ring is bonded to the hub after the vacuum sealing step.

In some implementations, an apparatus comprises a pipe, a stud that is forge-welded to the pipe, creating a forge-welded stud, a bracket that is operably coupled to the forge-welded stud, and a ladder support operably coupled to the bracket.

An automated system, method and tool for portable friction welding is disclosed for joining a rotatable workpiece to a substrate. A control system is disclosed receiving a start input to cause a motor to rapidly spin the workpiece and initiate a first thrust building cycle acting through an actuator to progressively force the spinning workpiece against the substrate. The materials at this intersection heat and plasticize and the actuator translates toward the substrate until the end of the desired actuator stroke operates to cut the motor off and to initiate and then hold a second axial thrust cycle on the actuator and there through to the interface of the workpiece and substrate. A reset input at the end of a cool off phase releases the thrust in the actuator.

An automated system, method and tool for portable friction welding is disclosed for joining a rotatable workpiece to a substrate. A control system is disclosed receiving a start input to cause a motor to rapidly spin the workpiece and initiate a first thrust building cycle acting through an actuator to progressively force the spinning workpiece against the substrate. The materials at this intersection heat and plasticize and the actuator translates toward the substrate until the end of the desired actuator stroke operates to cut the motor off and to initiate and then hold a second axial thrust cycle on the actuator and there through to the interface of the workpiece and substrate. A reset input at the end of a cool off phase releases the thrust in the actuator.

Systems and methods for joining a substrate of metallic material to a substrate of ceramic material using friction stir welding are provided. In one example, a method includes arranging an edge of the substrate of metallic material next to an edge of the substrate of ceramic material, and advancing a spinning engagement element of a friction stir welding tool through an edge zone of the substrate of metallic material located adjacent the edge of the substrate of metallic material, thereby to form a friction stir weld between the substrate of metallic material and the substrate of ceramic material. The method may also include advancing the spinning engagement element through the edge zone of the substrate of metallic material without touching, by the engagement element, the edge of the substrate of ceramic material.

A joining method includes the steps of placing a brazing element between an interface area of a first ceramic piece and an interface area of a second ceramic piece to create a joining pre-assembly, placing the components of said joining pre-assembly into a process chamber, removing oxygen from said process chamber, and heating at least said brazing element of said joining pre-assembly, thereby hermetically joining said first ceramic piece to said second ceramic piece. The brazing element consists of Nickel and Carbon.