A wire guide conduit is constructed from a coiled wire having an oval or elliptical cross-sectional shape. The wire is subjected to a directed energy beam to locally heat portions of the wire to create discrete areas of increased hardness in the surface of the wire. The wire is coiled to present the locally hardened regions on an inside passageway of the conduit. The wire guide conduit may be used in additional applications such as a control wire for an actuation system.

In various embodiments, wire composed at least partially of arc-melted refractory metal material is utilized to fabricate three-dimensional parts by additive manufacturing.

In various embodiments, wire composed at least partially of arc-melted refractory metal material is utilized to fabricate three-dimensional parts by additive manufacturing.

The example methods and apparatus reduce and/or eliminate adverse effects of welding work pieces having dissimilar compositions. An example method includes depositing a first weld layer on a first end of a first work piece. The first work piece has a first content of a metallic element and the first weld layer has a second content of the metallic element higher than the first content. The example method includes depositing a second weld layer between the first weld layer and a second end of a second work piece to couple the first work piece to the second work piece. The second weld layer has a third content of the metallic element higher than the second content, and the second work piece has a fourth content of the metallic element higher than the first content.

The example methods and apparatus reduce and/or eliminate adverse effects of welding work pieces having dissimilar compositions. An example method includes depositing a first weld layer on a first end of a first work piece. The first work piece has a first content of a metallic element and the first weld layer has a second content of the metallic element higher than the first content. The example method includes depositing a second weld layer between the first weld layer and a second end of a second work piece to couple the first work piece to the second work piece. The second weld layer has a third content of the metallic element higher than the second content, and the second work piece has a fourth content of the metallic element higher than the first content.

The present invention is an apparatus and method for replacing used electrode tips of a TIG welder. The apparatus has a main housing structure with a socket adapter assembly that is operatively supported by the main housing structure. The socket adapter assembly is used to both remove and re-attach the gas shield and the electrode nut of the TIG welder. A vacuum tip suction device that is operatively supported by the main housing structure is used to both remove and install electrode tips for the TIG welder.

The present invention is an apparatus and method for replacing used electrode tips of a TIG welder. The apparatus has a main housing structure with a socket adapter assembly that is operatively supported by the main housing structure. The socket adapter assembly is used to both remove and re-attach the gas shield and the electrode nut of the TIG welder. A vacuum tip suction device that is operatively supported by the main housing structure is used to both remove and install electrode tips for the TIG welder.

Various embodiments of a metal cored wires and methods are disclosed. In one embodiment of the present invention, a metal cored wire comprises a metal sheath and a metal-powder core material comprising manganese particles. The manganese particles are coated with a coating material to reduce the manganese fumes and exposure during welding.

Various embodiments of a metal cored wires and methods are disclosed. In one embodiment of the present invention, a metal cored wire comprises a metal sheath and a metal-powder core material comprising manganese particles. The manganese particles are coated with a coating material to reduce the manganese fumes and exposure during welding.

In various embodiments, three-dimensional layered metallic parts are substantially free of gaps between successive layers, are substantially free of cracks, and have densities no less than 97% of the theoretical density of the metallic material.