Weld metals and methods for welding ferritic steels are provided. The weld metals have high strength and high ductile tearing resistance and are suitable for use in strain based pipelines. The weld metal contains retained austenite and has a cellular microstructure with cell walls containing lath martensite and cell interiors containing degenerate upper bainite. The weld metals are comprised of between 0.02 and 0.12 wt % carbon, between 7.50 and 14.50 wt % nickel, not greater than about 1.00 wt % manganese, not greater than about 0.30 wt % silicon, not greater than about 150 ppm oxygen, not greater than about 100 ppm sulfur, not greater than about 75 ppm phosphorus, and the balance essentially iron. Other elements may be added to enhance the properties of the weld metal. The weld metals are applied using a power source with current waveform control which produces a smooth, controlled welding arc and weld pool in the absence of CO.sub.2 or oxygen in the shielding gas.

An exterior panel is formed of superplastic materials, including an exterior skin of titanium to accommodate high thermal stresses imposed on hypersonic transport vehicles during hypersonic flight. The exterior skin is fixed to an underlying reinforcing skeletal structure consisting of a superplastic formable reinforcement (SFR) layer, for example a titanium, zirconium, and molybdenum (TZM) alloy, which supports the exterior skin whenever the latter may be heated to temperatures exceeding 1200 degrees Fahrenheit. The exterior panel includes a separate interior skin configured for attachment to a frame member such as a rib, stringer, or spar of the hypersonic transport vehicle. A multicellular core is sandwiched between the exterior and interior skins to impart tensile and compressive strength to the exterior panel. In one disclosed method, the core is superplastic formed and diffusion bonded to the exterior and interior skins.

A metal case has a bottom part composed of a metal plate, and a side wall part composed of a metal plate that stands from an outer peripheral edge of the bottom part. A boundary part between the bottom part and the side wall part includes a welding portion formed by welding the both parts together. The welding portion is exposed on a surface of the metal case on a lower side in a standing direction of the side wall part. And, a lower end that is a lower end part of the bottom part in the standing direction of the side wall part is located on the lower side in the standing direction than the welding portion is.

A structural member includes a body having a first surface, a second surface, and an end surface at an end portion of the structural member. The end portion of the structural member includes a root protrusion extending radially outward from the second surface of the structural member along a root protrusion radius to an outer end of the root protrusion to define a root protrusion height extending from the second surface of the structural member to the outer end of the root protrusion. The root protrusion further includes a root protrusion width extending between an inner edge and an outer edge of the outer end of the root protrusion. The root protrusion radius, the root protrusion height, and the root protrusion width are configured to define a stress protected weld root region isolated beyond and away from a root stress flow path propagated through the body of the structural member.

A turbine is provided comprising a plurality of stages, each stage comprising a rotatable disk and blades carried thereby, at least one pair of adjacent rotatable disks defining an annular gap therebetween and having respective opposing sealing band receiving slots aligned with the annular gap A sealing band is located in the opposing receiving slots to seal the annular gap Disk engagement structure is defined in the pair of adjacent rotatable disks. A clip member is coupled to the sealing band and engaged with the pair of adjacent rotatable disks through the disk engagement structure The clip member may have an aperture extending only partially through the clip member for alignment with a hole in the sealing band for engagement with a tool To improve weld geometry, the clip member may have angled surfaces and notched areas, and the sealing band may have chamfered edges.

A sensor device includes a body case provided with an opening, and a body cover assembled to the body case to cover the opening. The body cover has at an outer peripheral portion thereof an overlapping region overlapping a portion of the body case located at a peripheral edge of the opening. The body cover is fixed to the body case by providing a welded portion surrounding the opening using laser-welding at a portion distant from an end surface of the body cover in a boundary of the overlapping region of the body cover and a portion of the body case overlapping the overlapping region.

A welding method includes: forming one or more lower plate grooves having a predetermined width and a predetermined depth at one side of an upper surface of a lower plate; forming one or more upper plate grooves having a predetermined width and a predetermined depth at one side of a lower surface of an upper plate; overlapping the lower plate and the upper plate so that the lower plate grooves of the lower plate and the upper plate grooves of the upper plate mesh with one another; and performing welding to form a bead at a welding part.

A tube assembly includes at least first and second tubes configured for coupling at respective ends. The first and second tubes each include a base material, and a weld interface at the respective end. The weld interface is proximate to an inner diameter and an outer diameter of the first and second tubes, and includes a weld interface segment extending therebetween. A work hardened weld assembly couples the base material of each of the first and second tubes. The work hardened weld assembly includes a weld fusion zone between the weld interfaces of the first and second tubes and the weld interface segments of the first and second tubes. The weld fusion zone is work hardened and at least the weld interface segments of the first and second tubes are work hardened between the work hardened weld fusion zone and the base material of the first and second tubes.

Method of manufacturing first structural component for or joining with second structural component by groove weld is provided. The first structural component has first surface, second surface and end portion. The component is bent at end portion to form bent portion defining convex and concave faces. First portion of bent portion is removed at convex face in form outer weld surface having first face extending from first surface, and second face connected to first face. Second portion of bent portion is removed at concave face to form inner edge surface having arcuate profile. Inner edge surface extends from second surface and connects to second face via transition portion. A portion of first face, second face, transition portion, and inner edge surface define root protrusion, having a root protrusion height, for first structural component. The root protrusion defines stress protected weld root region isolated beyond and away from root stress flow path.

A method of fusion welding two ferrous alloy component parts, at least one of which is considered unweldable, involves placing a low carbon steel band into a groove defined in part by each of the ferrous alloy component parts and then conveying a concentrated energy source along a welding line that overlaps the low carbon steel band to melt the steel band along with adjacent portions of the ferrous alloy component parts to form a blended alloy weld pool. The blended alloy weld pool solidifies behind the forward movement of the concentrated energy source into a weld joint that fusion welds the ferrous alloy component parts together. The ferrous alloy component parts may include a differential casing and a ring gear. In that regard, a differential casing and ring gear assembly that includes a weld joint is also disclosed.