A method of joining a first piece of an automotive component that is made from a first material to a second piece of the automotive component that is made from a second material includes machining a fay surface onto each of the first and second pieces of the automotive component, cleaning the fay surfaces of each of the first and second pieces of the automotive component, placing a metal filler between the fay surfaces of the first and second pieces of the automotive component, holding the first and second pieces together with the metal filler positioned between the fay surfaces of the first and second pieces, and passing an electric current through the first piece, the metal filler and the second piece to melt the metal filler and weld the first piece to the second piece.

Methods, systems, and apparatuses for component manufacturing are provided. A component may be manufactured via an extrusion of loose substrate material into a unitary tubing. Features may be added to the tubing via friction stir additive manufacturing to manufacture a component. In this manner, a component may be manufactured from titanium alloys while processing challenges such as iron segregation or material loss through machining are ameliorated. Such a component may replace steel or other high strength components and further exhibits corrosion resistance.

A method of joining parts, where at least one of the parts has a faying surface defining grooves therein. One of the parts is formed of a majority of titanium, and the other part is formed of a majority of iron. The method includes providing a set of opposed welding electrodes disposed on a side of each part and applying pressure to and heating the parts via the set of electrodes to form a joint between the parts. A bonded assembly includes a first part formed of a majority of titanium and a second part formed of a steel alloy. The first and second parts having a bond that includes a portion of the first part directly in contact with and attached to a portion of the second part. The parts may be a titanium-containing differential carrier case bonded to a steel gear.

A method of joining a first piece of an automotive component that is made from a first material to a second piece of the automotive component that is made from a second material includes machining a fay surface onto each of the first and second pieces of the automotive component, cleaning the fay surfaces of each of the first and second pieces of the automotive component, placing a metal filler between the fay surfaces of the first and second pieces of the automotive component, holding the first and second pieces together with the metal filler positioned between the fay surfaces of the first and second pieces, and passing an electric current through the first piece, the metal filler and the second piece to melt the metal filler and weld the first piece to the second piece.

The objective of the present invention is to provide a friction pressure welding method with which the welding temperature can be controlled accurately, the welding temperature can be lowered, and the distribution of the welding temperature at an interface to be welded can be made uniform; and to provide a welded structure obtained by this method. The present invention relates to the friction pressure welding method in which one member is abutted against another member and is made to slide in a state in which a welding pressure substantially perpendicular to the interface to be welded is applied, said friction pressure welding method being characterized in that the maximum sliding speed is no greater than 53 mm/sec, the difference in the temperature increase rate between a center portion and an outer peripheral portion at the interface to be welded is 10° C./sec or less, and the difference between the maximum attained temperature between the center portion and the outer peripheral portion at the interface to be welded is no greater than 50° C.

A friction stir processing (FSP) tool includes a working material. The working material has a matrix phase and a particulate phase. The matrix phase includes tungsten and an alloy material. The particulate phase is located within the matrix phase, and the particulate phase has an indentation hardness less than 45 GPa.

A joint structure includes: a first same-type metal member; a second same-type metal member that can be mutually welded with the first same-type metal member; and a different-type member that has a penetrating portion, is interposed between the first same-type metal member and the second same-type metal member. In the plate thickness direction of an emission region in which a laser beam is emitted toward the penetrating portion, the plate thickness at the emission region of the first same-type metal member positioned on the side on which the laser beam is emitted is a predetermined thickness corresponding to a first gap. The first same-type metal member and the second same-type metal member are fused and bonded together via the penetrating portion, and the different-type member is compressed and fixed, such that the different-type member is fixed to the first same-type metal member and the second same-type metal member.

An additive manufacturing system includes an additive manufacturing tool configured to receive a plurality of metallic anchoring materials and to supply a plurality of droplets to a part, and a controller configured to independently control the composition, formation, and application of each droplet to the plurality of droplets to the part. The plurality of droplets is configured to build up the part. Each droplet of the plurality of droplets includes at least one metallic anchoring material of the plurality of metallic anchoring materials.

A tube and tubesheet assembly is provided, which includes a tubesheet, the tubesheet comprising at least one tube insertion aperture therethrough; at least one tube inserted in the at least one tube insertion aperture; and a damage-resistant layer applied to an edge of the at least one tube and along an inner surface of a portion of the tube that is positioned within the corresponding tube insertion aperture. A heat exchanger including the assembly is also provided. A method is also provided for coupling a tube to a tubesheet. The method includes applying a damage-resistant layer to an edge of the tube and along an inner surface of a portion of the tube that is positioned within a tube insertion aperture in the tubesheet. The method can also be used to repair tubes and retrofit pre-existing tube-to-tubesheet joints.

A system includes a layered structure. The layered structure includes first and second coalesced layers and an intermediate layer disposed between the first and second coalesced layers. The first and second coalesced layers have a higher degree of coalescence than the intermediate layer.