Abstract: An ultrasonic machining module that includes an ultrasonic transducer, wherein the ultrasonic transducer is adapted to receive a machining tool; a vibration-isolating housing adapted to be both compatible with a machining system and to receive the ultrasonic transducer therein, wherein the housing further includes at least one modification for isolating all vibrations generated by the ultrasonic transducer when the device is in operation except axial vibrations transmitted to the machining tool, thereby preventing unwanted vibrations from traveling backward or upward into the machining system; and a connector in electrical communication with the ultrasonic transducer, wherein the connector is operative to supply electrical energy to the ultrasonic transducer, and wherein the connector is adapted to rotate at a predetermined rate of speed.

Abstract: An ultrasonic machining module that includes an ultrasonic transducer, wherein the ultrasonic transducer is adapted to receive a machining tool and a vibration-isolating housing adapted to be both compatible with a machining system and to receive the ultrasonic transducer therein, wherein the housing further includes at least one modification for isolating all vibrations generated by the ultrasonic transducer when the device is in operation except axial vibrations transmitted to the machining tool, thereby preventing unwanted vibrations from traveling backward or upward into the machining system. The ultrasonic machining module may also include an acoustically tuned collet and/or an acoustically tuned system for delivering coolant fluid through the module to a machining tool or target substrate.

Abstract: An ultrasonic machining module that includes an ultrasonic transducer, wherein the ultrasonic transducer is adapted to receive a machining tool and a vibration-isolating housing adapted to be both compatible with a machining system and to receive the ultrasonic transducer therein, wherein the housing further includes at least one modification for isolating all vibrations generated by the ultrasonic transducer when the device is in operation except axial vibrations transmitted to the machining tool, thereby preventing unwanted vibrations from traveling backward or upward into the machining system.

Abstract: A method for reducing areas of friction within a forming die that includes identifying at least one region of interest in the forming die, wherein the at least one region of interest further includes a problematic aspect of a predetermined nature; designing a die segment corresponding to the at least one region of interest, wherein the die segment further includes at least one ultrasonic transducer embedded therein; modifying the forming die to receive the die segment; installing the die segment in the forming die and acoustically isolating the die segment from the remainder of the forming die; and energizing the ultrasonic transducer to provide ultrasonic energy to the die segment, wherein providing ultrasonic energy to the die segment addresses the problematic aspect of the at least one region of interest in the forming die.

Abstract: A friction stir welding tool includes that a body and a pin formed integrally with the body at one end thereof. The body and pin further include a first material and a second material; wherein the first material further includes a molybdenum-based refractory alloy; and wherein the second material further includes hafnium, lanthanum, carbon, titanium, zirconium, or combinations thereof.

Abstract: A gas metal arc welding system that includes leading and trailing welding torch assemblies arranged to operate in tandem. The leading welding torch assembly further includes a torch body; a contact tip connected to one end of the rotatable torch body, wherein the contact tip further includes a passage formed therethrough; a consumable wire electrode passing through the body and exiting the contact tip through an exit hole; and a source of shielding gas. The trailing welding torch assembly further includes a non-rotatable torch body; a contact tip connected to one end of the non-rotatable torch body; a consumable wire electrode passing through the non-rotatable torch body and exiting through the contact tip; and a source of shielding gas.

Abstract: A system for characterizing a spot weld including an acoustic probe that further includes a plurality of ultrasonic transducer elements arranged in a curved array, wherein the transducer elements are operative to generate ultrasonic signals and to receive reflections thereof; and a combination of materials for allowing the probe to conform to a contoured surface of the spot weld while enabling sound energy to be transferred directly into the spot weld under test conditions; a phased array excitation unit coupled to the array of transducer elements for ultrasonically exciting transducer elements; and a controller coupled to the phased array excitation unit for controlling the operation of the phased array unit, gathering and processing information from the ultrasonic transducers, and generating a two-dimensional, color coded image that characterizes the integrity of the spot weld.

Abstract: A gas metal arc welding system that includes first and second welding torch assemblies arranged to operate in tandem. The first welding torch assembly further includes a rotable torch body; a contact tip connected to one end of the rotatable torch body, wherein the contact tip further includes an angled passage formed therethrough; a consumable wire electrode passing through the rotating torch body and exiting the contact tip through the offset exit hole; and a source of shielding gas. The second welding torch assembly further includes a non-rotatable torch body; a contact tip connected to one end of the non-rotatable torch body; a consumable wire electrode passing through the non-rotatable torch body and exiting through the contact tip; and a source of shielding gas.

Abstract: A portable system for non-destructively characterizing spot welds that includes at least one matrix phased array probe and a body, wherein the body is designed to be hand-held and further includes an ergonomically designed outer casing; at least one input for connecting to the at least one matrix phased array probe; ultrasonic phased array transmitting and receiving circuitry in electrical communication with the at least one input; a touch screen computer that further includes at least one data processor running software that includes at least one imaging algorithm for processing data received from the probe and generating color coded ultrasonic C-scan images of characterized welds; and at least one monitor for displaying the color coded ultrasonic C-scan images of the characterized welds in real time.

Abstract: A system for training welders that includes a data generating component, a data capturing component and a data processing and visualization component. The data generating component operates in real time and derives data from an actual manually-executed weld and further includes a weld process-specific jig, a calibration block positioned on the jig, wherein the geometric configuration of the calibration block is specific to a particular type of weld joint, a weld coupon positioned on the welding process-specific jig adjacent to the calibration block, a welding gun for use by a trainee, wherein the welding gun is operative to form the weld; and at least one target mounted on the welding gun that is recognized by the data processing and visualization component for providing multidimensional position and orientation feedback to the trainee.

Abstract: A system for inspecting the surface of a curved object is provided. This system includes an object having a curved surface; at least one substantially flat interdigital transducer, wherein the interdigital transducer is operative to generate surface energy waves; and at least one coupling device disposed between the curved surface and the substantially flat interdigital transducer, wherein the coupling device is operative to conform to the curved surface, support the interdigital transducer, and provide a medium through which the surface energy waves can effectively travel from the interdigital transducer to the curved surface and across the curved surface in a predetermined direction.

Abstract: A machining system that includes an ultrasonic machining assembly, wherein the ultrasonic machining assembly further includes a machining tool; a collet adapted to receive the machining tool; and an ultrasonic transducer, wherein the ultrasonic transducer is operative to transmit acoustical vibrations to the machining tool; and a machining apparatus, wherein the machining apparatus is adapted to receive and secure the ultrasonic machining assembly, and wherein the machining apparatus is operative to transmit torque to the machining tool by applying rotary motion to the ultrasonic machining assembly.

Abstract: A device for use in a machining system, including an ultrasonic transducer, wherein the ultrasonic transducer is adapted to receive a tool bit; a housing adapted to be both compatible with the machining system and to receive the ultrasonic transducer, wherein the housing is operative to isolate all radial and other vibrations generated by the ultrasonic transducer except the axial vibrations transmitted to the tool bit; and a tool holder, wherein the tool holder and the top portion of the housing are mechanically coupled to one another.

Abstract: A friction stir welding tool includes that a body and a pin formed integrally with the body at one end thereof. The body and pin further include a first material and a second material; wherein the first material further includes a molybdenum-based refractory alloy; and wherein the second material further includes hafnium, lanthanum, carbon, titanium, zirconium, or combinations thereof.

Abstract: A portable system for non-destructively characterizing spot welds that includes at least one matrix phased array probe and a body, wherein the body is designed to be hand-held and further includes an ergonomically designed outer casing; at least one input for connecting to the at least one matrix phased array probe; ultrasonic phased array transmitting and receiving circuitry in electrical communication with the at least one input; a touch screen computer that further includes at least one data processor running software that includes at least one imaging algorithm for processing data received from the probe and generating color coded ultrasonic C-scan images of characterized welds; and at least one monitor for displaying the color coded ultrasonic C-scan images of the characterized welds in real time.

Abstract: A non-destructive system for characterizing welds that includes at least one weldment that further includes at least two components joined together a weld; at least one source of heat energy directed toward one side of the weldment, wherein the source of heat energy is operative to direct a predetermined amount of heat energy through the first component toward one side of the weld, through the weld and the area surrounding the weld, and through the second component to the opposite side of the weldment, and wherein the heat energy is sufficient to induce a temperature change in the weld and the area surrounding the weld; and a temperature measuring device directed toward the opposite side of the weldment for gathering temperature data from heat passing through the second component away from the weld and the area surrounding the weld, wherein the gathered temperature data is indicative of weld quality.

Abstract: A system for joining materials such as metal alloys that includes a first component, wherein the first component includes a first alloy having a known austenization temperature below which martensite forms when the component is heated and then cooled at a predetermined rate of cooling; a second component, wherein the second component includes a second alloy; and a welding apparatus operative to create a weld between the first and second components without crossing the austenization temperature of the first alloy.

Abstract: A laser scanner system for removing a coating from a surface.

Abstract: A high-powered laser beam focusing apparatus for use in laser welding applications that includes a laser having a beam delivery fiber for generating a laser beam and a housing adapted to receive the beam delivery fiber. The housing further includes a first internal chamber adapted to receive a flow of pressurized gas; a second internal chamber; and an aerodynamic window positioned between the first chamber and the second chamber.

Abstract: A system and method for creating computerized models of forming processes, wherein forming process parameters including material type, material geometry, forming method, incoming material properties, forming die geometry, forming die thermal management method, lubrication method, forming rate, material constraint conditions, incoming material temperature, and other possible parameters are preselected by a user.