A second member is made of a material difficult to be welded to a first member. A first step includes forming a third member by welding a first filler material to the first member through a through-portion of the second member. A second step includes forming a fourth member by covering a surface of the third member with a second filler material and welding the fourth member to the second member.

A hybrid bumper assembly for a vehicle includes a steel reinforcement beam and aluminum crush cans attached to end portions of the steel reinforcement beam. The reinforcement beam has a multi-tubular shape that is formed by a high-strength steel sheet that is roll formed to provide at least two tubular portions. A crush can has an interfacing portion that is coupled to an end portion of the reinforcement beam. The end portions of the reinforcement beam and the interfacing portion of the crush cans may be configured to attach together using a select joining technology in a manner that minimizes or eliminates bimetallic or galvanic corrosion between the reinforcement beam and the crush cans.

The invention relates to a method for producing an electrically conductive connection between a copper component 23, 23a and an aluminum component 24 by means of cold metal transfer welding, in which a welding wire is periodically moved back and forth from the material of a component to be welded.

A method of manufacturing a knife blade includes preparing a blade preform of a first material, depositing a second material which is harder than the first material on an edge of the blade preform by arc welding, and sharpening the deposited second material to prepare a knife blade with a sharp edge. A knife blade is also provided and includes a blade section of a first material, and an edge of the blade section is provided with an arc welded layer of a second material which is shaped as a sharp edge, where the second material is harder than the first material.

The present disclosure relates to a welding composition for joining high manganese steel base metals to low carbon steel base metals, as well as systems and methods for the same. The composition includes: carbon in a range of about 0.1 wt % to about 0.4 wt %; manganese in a range of about 15 wt % to about 25 wt %; chromium in a range of about 2.0 wt % to about 8.0 wt %; molybdenum in an amount of ≦ about 2.0 wt %; nickel in an amount of ≦ about 10 wt %; silicon in an amount of ≦ about 0.7 wt %; sulfur in an amount of ≦ about 100 ppm; phosphorus in an amount of ≦ about 200 ppm; and a balance comprising iron. In an embodiment, the composition has an austenitic microstructure.

A method of joining an aluminum workpiece and an adjacent overlapping steel workpiece by reaction metallurgical joining, and the resultant metallurgical joint formed between the two workpieces, are disclosed. The method involves compressing a reaction material located between the aluminum and steel workpieces and heating the reaction material momentarily to form a metallurgical joint that comprises bonding interface between the reaction material and the steel workpiece and a bonding interface between the reaction material and the aluminum workpiece. The reaction material is formulated to be able to interact with both aluminum and steel in order to establish the bonding interfaces of the metallurgical joint. Moreover, the practice of oscillating wire arc welding may be employed to deposit the reaction material in the form of a reaction material deposit onto the steel workpiece prior to assembling the steel and aluminum workpieces in a workpiece stack-up.

A gear includes an inner portion formed from a first material; an outer portion formed from a second material melted and solidified onto the inner portion; and a plurality of teeth formed in the outer portion after the second material has solidified.

A gear includes an inner portion formed from a first material; an outer portion formed from a second material melted and solidified onto the inner portion; and a plurality of teeth formed in the outer portion after the second material has solidified.

Second member 20 includes a material that is difficult to weld to first member 10. In first member 10, recess 11 is formed by press molding such that a lower surface of first member 10 opposite to second member 20 protrudes.

Third member 30 is arc-welded toward at least a bottom of recess 11 via penetrating part 21 of second member 20. Second member 20 is compressed by flange 31 and first member 10 by solidification contraction of third member 30, and second member 20 is therefore fixed between flange 31 of third member 30 and first member 10.

A joint structure includes a first metallic material having a first projection, a second metallic material similar to and weldable to the first metallic material, and a different material having a first penetrating part and sandwiched between the first and second metallic materials, the different material being difficult to weld to the first and second metallic materials. The first projection is smaller than the first penetrating part and is spaced from the rim of the first penetrating part. The first projection is positioned in the first penetrating part and spaced from the second metallic material by a gap. The gap has a size of a predetermined percentage of the thickness of the first projection to which arc welding is applied. The first and second metallic materials are melted and joined together inside the first penetrating part to compress and fix the different material, so all three are fixed together.