Abstract: A system for fabricating silicon carbide assemblies that includes at least two silicon carbide materials; at least one joining interlayer positioned between the at least two silicon carbide materials, wherein the at least one joining interlayer further includes a first material that melts at a first temperature and a second material interspersed throughout the first material, and wherein the second material melts at a temperature that is lower than that of the first material; and at least one apparatus for applying energy to the joining interlayer, wherein applying energy to the joining interlayer is operative to soften the first material and melt the second material, and wherein softening the first material and melting the second material is operative to transform the joining interlayer into a substantially porosity-free adherent material capable of joining together the at least two silicon carbide materials.

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 system for characterizing manual welding exercises and providing valuable training to welders that includes components for generating, capturing, and processing data. The data generating component further includes a fixture, workpiece, at least one calibration devices each having at least two point markers integral therewith, and a welding tool. The data capturing component further includes an imaging system for capturing images of the point markers and the data processing component is operative to receive information from the data capturing component and perform various position and orientation calculations.

Abstract: A remote high-performance computing material joining and material forming modeling system (100) enables a remote user (10) using a user input device (20) to use high speed computing capabilities to model materials joining and material forming processes. The modeling system (100) includes an interface module (200), an application module (300), a computing module (400), and a scheduling module (500). The interface module (200) is in operative communication with the user input device (20), as well as the application module (300), the computing module (400), and the scheduling module (500). The application module (300) is in operative communication with the interface module (200) and the computing module (400). The scheduling module (500) is in operative communication with the interface module (200) and the computing module (400). Lastly, the computing module (400) is in operative communication with the interface module (200), the application module (300), and the scheduling module (500).

Abstract: An ultrasonic welding assembly, comprising a sonotrode, wherein the sonotrode further includes at least one welding region and at least one node adjacent to the welding region; a mount for supporting the sonotrode, wherein the mount further includes a force application region; at least one ultrasonic transducer connected to the sonotrode for transmitting acoustic vibrations to the at least one welding region; at least one roller connected to the sonotrode in a flexible manner for permitting rotation of the sonotrode about its axis; a device for maintaining axial alignment of the sonotrode relative to a target welding area; and a low-friction bearing in contact with the at least one node for the application of force thereto, wherein the at least one low-friction bearing is connected to the mount.

Abstract: A system for removing a coating from a surface is provided. This system includes a laser scanner, wherein the laser scanner further includes at least one laser source, wherein the at least one laser source is operative to generate at least one laser beam, and wherein the laser beam is directed onto a work surface by the laser scanner; and a controller for operating the laser scanner. The controller further includes an imaging device for imaging the work surface; a lighting device for illuminating the work surface and overwhelming light generated by the interaction of the laser beam with the work surface; and a processor for processing information collected by the imaging device and adjusting the power output of the at least one laser source, if and when desirable or necessary.

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: An ultrasonic welding assembly, comprising a sonotrode, wherein the sonotrode further includes at least one welding region and at least one node adjacent to the welding region; a mount for supporting the sonotrode, wherein the mount further includes a force application region; at least one ultrasonic transducer connected to the sonotrode for transmitting acoustic vibrations to the at least one welding region; at least one roller connected to the sonotrode in a flexible manner for permitting rotation of the sonotrode about its axis; a device for maintaining axial alignment of the sonotrode relative to a target welding area; and a low-friction bearing in contact with the at least one node for the application of force thereto, wherein the at least one low-friction bearing is connected to the mount.

Abstract: An ultrasonic welding assembly, comprising: a sonotrode having a single welding region and two nodal regions formed on either side of the welding region; a mounting plate for supporting the sonotrode having a force application region on the upper surface thereof; at least one ultrasonic transducer connected to the sonotrode; at least one diaphragm spring disposed between the ultrasonic transducer and the sonotrode; at least one roller bearing connected to the diaphragm spring; at least two linear guides connected to the roller bearing, wherein the at least two linear guides are connected to the mounting plate and support the roller bearing and the sonotrode in a flexible manner; and first and second low-friction linear bearings in contact with nodal regions for the application of downward force to the sonotrode, wherein the first and second linear bearings are connected to the mounting plate.

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: An ultrasonic welding assembly, comprising: a sonotrode having a single welding region and two nodal regions formed on either side of the welding region; a mounting plate for supporting the sonotrode having a force application region on the upper surface thereof; at least one ultrasonic transducer connected to the sonotrode; at least one diaphragm spring disposed between the ultrasonic transducer and the sonotrode; at least one roller bearing connected to the diaphragm spring; at least two linear guides connected to the roller bearing, wherein the at least two linear guides are connected to the mounting plate and support the roller bearing and the sonotrode in a flexible manner; and first and second low-friction linear bearings in contact with nodal regions for the application of downward force to the sonotrode, wherein the first and second linear bearings are connected to the mounting plate.

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 is provided, wherein the tool includes a body; a neck formed integrally with the body, wherein the outer diameter of the neck is less than the outer diameter of the body; and a frustoconical probe formed integrally with the neck, wherein the probe further includes a base and a tip, wherein the outer diameter of the tip is less than the outer diameter of the base, wherein the outer diameter of the base is less than the outer diameter of the neck, wherein the outer edge of the base and the outer edge of the neck define a shoulder region therebetween, and wherein the ratio of the outer diameter of the neck and the outer diameter of the base is within the range of about 1.5:1 to 1.25:1 or less.

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

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: The apparatus (50) includes a friction stir welding tool (100), a local clamping means (200), and an interface (300) that joins the tool (100) and the local clamping means (200). The local clamping means (200) is in close proximity to the at least one sidewall (130) of the tool (100) and has a housing (210) and a plurality of contact devices (220). The local clamping means (200) transfers a clamping force to the first and the second components (C1, C2) and holds them firmly in place during welding. The local clamping means (200) includes a plurality of contact devices (220) that may take the form of casters, rollers (222), and ball bearings (224). The location of the contact devices (220) is significant as external clamping is greatly reduced, and often eliminated, as the contact devices (220) are brought into close proximity to the area of the weld.

Abstract: A method of friction stir welding and a non-consumable multi-section faced retractable shoulderless variable penetration friction stir welding tool. The tool includes a substantially cylindrical body portion, a head portion, and a tip section, each integral to the tool. The body portion has a longitudinal axis about which it is rotable, a diameter, a sidewall substantially parallel to the longitudinal axis, a proximal end, and a distal end. The head portion is located at the distal end of the body portion. The head portion includes a multi-section face, having a first face section and a second face section, that converges to the tip section. The tool is retractable, reduces overheating, improves weld quality by reducing internal voids and lack of fusion, and facilitates variable penetration welds.

Abstract: A method of friction stir welding and a non-consumable retractable shoulderless variable penetration friction stir welding tool. The tool includes a substantially cylindrical body portion, a head portion, and a tip section, each integral to the tool. The body portion has a longitudinal axis about which it is rotable, a diameter, a sidewall substantially parallel to the longitudinal axis, a proximal end, and a distal end. The head portion is located at the distal end of the body portion. The head portion has a base with a diameter substantially equal to the diameter of the body portion thereby forming a smooth transition between the body portion and the head portion, thus the tool has no shoulder. The head portion includes a face that converges to the tip section. The tool is retractable, reduces overheating, improves weld quality by reducing internal voids and lack of fusion, and facilitates variable penetration welds.

Abstract: An opposed current flow magnetic pulse forming and joining system in electrical communication with a magnetic pulse power supply having a positive connection and a negative connection. The system may be used in forming individual workpieces or joining multiple workpieces, including joining by magnetic pulse welding. The system includes a first section, a second section, an insulator, and a first and a second pair of conductors. The first and second sections cooperate to enclose the workpiece(s) and function to create an electromagnetic force similar to that produced by a single closed coil. The system is configured to achieve desirable current flow by minimizing inductance, inductive reactance, and impedance in the conductors. The pairs of conductors may incorporate closely spaced individual conductors, braided conductors, and coaxial conductors. The current flow in the individual conductors of each pair of conductors is opposed, as is the current flow through the sections.

Abstract: A method of friction stir welding and a non-consumable retractable shoulderless variable penetration friction stir welding tool. The tool includes a substantially cylindrical body portion, a head portion, and a tip section, each integral to the tool. The body portion has a longitudinal axis about which it is rotable, a diameter, a sidewall substantially parallel to the longitudinal axis, a proximal end, and a distal end. The head portion is located at the distal end of the body portion. The head portion has a base with a diameter substantially equal to the diameter of the body portion thereby forming a smooth transition between the body portion and the head portion, thus, the tool has no shoulder. The head portion includes a face that converges to the tip section. The tool is retractable, reduces overheating, improves weld quality by reducing internal voids and lack of fusion, and facilitates variable penetration welds.