Abstract: Disclosed are aluminum alloy products and methods of making and processing such products. Thus, disclosed are aluminum alloy products exhibiting controllable surface properties, including excellent bond durability, low contact resistance, and corrosion resistance. Aluminum alloy products described herein include a migrant element, a subsurface portion having a concentration of the migrant element, and a bulk portion having a concentration of the migrant element. The aluminum alloy product comprises an enrichment ratio of 4.0 or less, wherein the enrichment ratio is a ratio of the migrant element concentration in the subsurface portion to the concentration in the bulk portion. Additionally, the aluminum alloy products surface and/or subsurface can contain phosphorus (e.g., elemental phosphorus or oxidized phosphorus). The phosphorus containing surface provides reduced electronic stress on an electrode tip of a resistance spot welding apparatus, and an extended service lifetime (e.g.

Abstract: A method for forming a vertically cracked thermal barrier coating is disclosed including positioning an article relative to a heat source. The article includes a thermal barrier coating disposed on a first surface of a substrate, and the substrate includes a second surface distal across the substrate from the first surface. Heat is applied locally to at least one discrete portion of the second surface of the substrate. At least one vertical crack in the thermal barrier coating is formed disposed over the at least one discrete portion. An article is disclosed including a substrate and a vertically-cracked thermal barrier coating disposed on the substrate. The vertically cracked thermal barrier coating includes at least one vertical crack in the thermal barrier coating and at least one of a low density of less than 85% of a theoretical density for the thermal barrier coating and a selective crack distribution.

Abstract: A metal joiner system includes a power source and a metal joiner. The metal joiner includes a cleaning header, a cutting header, a joining header, and a joint finisher, each of which are communicatively coupled to the power source. The cutting header and cleaning header are configured to direct a first laser beam to prepare a joining region, and the joining header is configured to direct a second laser beam to form a joint in the joining region. A method of joining a metal substrates includes forming a joining region in abutting metal substrates, directing the first laser beam onto the joining region in a joint preparation stage, and directing the second laser beam onto the joining region to form a weld. A product of a metal joiner, a weld, has a portion of weld metal removed at the weld start and the weld crater regions.

Abstract: Hybrid welding methods include directing a laser beam from a laser onto a first component that is vertically offset from a second component, and, directing a weld arc from an arc welder onto a weld joint between the first component and the second component to weld the first and second components together.

Abstract: In some embodiments, a method of welding includes welding at least one fill bead to fill at least one gap on a substrate with arc scanning by an arc welder. The gap is defined by at least one weld bead on the substrate. The weld beads are non-overlapping. A welded article includes a substrate including a crack-prone superalloy and at least one weld bead and at least one fill bead welded on the substrate. The fill bead, the weld bead, and a heat-affected zone of the substrate are micro-crack-free and macro-crack-free. In some embodiments, a method of welding includes welding weld beads on a substrate and welding fill beads on the substrate with an arc welder while arc scanning. The fill beads fill the gaps between neighboring pairs of weld beads. The fill beads are welded in a non-sequential order.

Abstract: A method for closing a hole penetrating a hole height from a first surface of a metal article through a second surface of the metal article is disclosed including removing a portion of the metal article surrounding the hole from the metal article. The portion includes a depth extending from the first surface into the metal article and terminating prior to the second surface. Removing the portion forms a support surface within the hole adjacent and opposite to the second surface. A metal support structure is disposed within the hole on the support surface, and a metal composition is applied into the hole and onto the metal support structure. The metal support structure, the metal composition, and the metal article are fused together.

Abstract: A method for closing a plurality of holes penetrating from a first surface of a metal article through a second surface of the metal article is disclosed including applying the metal composition to the first surface along a bridging application path. The bridging application path passes over the plurality of holes between a first edge of each of the plurality of holes and a second edge of each of the plurality of holes. Applying the metal composition along the bridging application path closes the plurality of holes.

Abstract: A method for hardfacing a metal article is disclosed including applying a first pass of a metal composition to a surface of the metal article along a first application path, applying a second pass of the metal composition to the surface along a second application path, and applying a third pass of the metal composition to the surface along a third application path between the first application path and the second application path. The first pass and the second pass form a hardfacing perimeter, and the third pass fills in the hardfacing perimeter.

Abstract: Manufactured articles, and methods of manufacturing enhanced wear protected components and articles. More particularly, wear protected components and articles, such as combustor components of turbine engines, and even more particularly enhanced wear protected micromixer tubes and assemblies thereof with one or more micromixer plates, the micromixer tubes having wear protection for enhanced performance and reduced wear related failure. Methods including surface treatment to enhance wear, including vacuum braze application of coatings to enhance surface hardness for wear benefits.

Abstract: A process of welding a weld turbulator on an article includes forming a weld pool on a surface of the article using an arc welder, directing at least one beam of at least one beam welder to at least one fusion edge of the weld pool, and translating the arc welder and the beam welder in a weld direction to shape the weld pool into the weld turbulator extending in the weld direction and having the fusion edge. A turbulator welding system includes an arc welder arranged and disposed to provide an electric arc on a surface of an article to form a weld pool and at least one beam welder arranged and disposed to provide at least one beam to at least one fusion edge of the weld pool. A component includes an article having a surface and a weld turbulator on the surface of the article.

Abstract: Disclosed are aluminum alloy products and methods of making and processing such products. Thus, disclosed are aluminum alloy products exhibiting controllable surface properties, including excellent bond durability, low contact resistance, and corrosion resistance. Aluminum alloy products described herein include a migrant element, a subsurface portion having a concentration of the migrant element, and a bulk portion having a concentration of the migrant element. The aluminum alloy product comprises an enrichment ratio of 4.0 or less, wherein the enrichment ratio is a ratio of the migrant element concentration in the subsurface portion to the concentration in the bulk portion. Additionally, the aluminum alloy products surface and/or subsurface can contain phosphorus (e.g., elemental phosphorus or oxidized phosphorus). The phosphorus containing surface provides reduced electronic stress on an electrode tip of a resistance spot welding apparatus, and an extended service lifetime (e.g.

Abstract: A welding process, welding system and welded article are disclosed. The welding process includes generating a first beam from a stationary fusion apparatus and generating a second beam from a rotatable fusion apparatus. The first beam and the second beam form a weld in an article. The welding system includes a stationary fusion apparatus and a rotatable fusion apparatus directed at an article to be welded, the stationary fusion apparatus and rotatable fusion apparatus being arranged and disposed to form a single weld in the article. The welded article includes a first element welded to a second element, the welded article having a decreased root reinforcement, in an inaccessible region, from that of a hybrid stationary fusion apparatus.

Abstract: A joining process and a joined article are disclosed. The joining process includes positioning an article having a base material, and friction joining a pre-sintered preform to the base material. The pre-sintered preform forms a feature on the article. The joined article includes a feature joined to a base material by friction joining of a pre-sintered preform.

Abstract: A method for forming a vertically cracked thermal barrier coating is disclosed including positioning an article relative to a heat source. The article includes a thermal barrier coating disposed on a first surface of a substrate, and the substrate includes a second surface distal across the substrate from the first surface. Heat is applied locally to at least one discrete portion of the second surface of the substrate. At least one vertical crack in the thermal barrier coating is formed disposed over the at least one discrete portion. An article is disclosed including a substrate and a vertically-cracked thermal barrier coating disposed on the substrate. The vertically cracked thermal barrier coating includes at least one vertical crack in the thermal barrier coating and at least one of a low density of less than 85% of a theoretical density for the thermal barrier coating and a selective crack distribution.

Abstract: Molded articles and methods for forming molded articles are provided. For example, a molded article comprises a first region formed by a first casting material and a second region formed by mixing a molten or liquid portion of the first casting material and a second casting material. The first casting material is a molten, liquid, or fluid metal alloy, and the second casting material is a molten or fluid metal alloy. The first casting material has a different chemical composition than the second casting material. The first region and the second region are cast as one integral casting using directional solidification, and the first region and the second region have different microstructure patterns. The molded article has a lower concentration of impurities than were present in the first and second casting materials, and an interface between the first region and the second region is devoid of an oxidation layer.

Abstract: Disclosed are welds formed from improved resistance spot welding, as well as methods of improved resistance spot welding. Resistance spot welding includes positioning a magnet carrier having a plurality of electromagnets on at least one electrode of two electrodes. The method includes positioning a first metal sheet and a second metal sheet between the two electrodes where at least one of the first metal sheet or the second metal sheet includes an aluminum alloy. The method includes positioning the forming a weld nugget by applying a magnetic field from the plurality of electromagnets through the weld while applying a current through the electrodes to stir a portion of the first metal sheet and the second metal sheet forming a weld nugget and adjusting the magnetic field to control at least one characteristic of the weld nugget. Forming the weld nugget joins the first metal sheet with the second metal sheet.

Abstract: A method for closing a plurality of holes penetrating from a first surface of a metal article through a second surface of the metal article is disclosed including applying the metal composition to the first surface along a bridging application path. The bridging application path passes over the plurality of holes between a first edge of each of the plurality of holes and a second edge of each of the plurality of holes. Applying the metal composition along the bridging application path closes the plurality of holes.

Abstract: A method for hardfacing a metal article is disclosed including applying a first pass of a metal composition to a surface of the metal article along a first application path, applying a second pass of the metal composition to the surface along a second application path, and applying a third pass of the metal composition to the surface along a third application path between the first application path and the second application path. The first pass and the second pass form a hardfacing perimeter, and the third pass fills in the hardfacing perimeter.

Abstract: A method for forming a turbine component is disclosed, including applying a metal composition to a structure by an additive manufacturing technique and lengthening the structure by the additive manufacturing technique. The structure is a transition piece or a combustion liner-transition piece assembly. Lengthening the structure forms a structure extension. A picture frame is formed on an outer surface of the structure extension by the additive manufacturing technique.

Abstract: A method for closing a hole penetrating a hole height from a first surface of a metal article through a second surface of the metal article is disclosed including removing a portion of the metal article surrounding the hole from the metal article. The portion includes a depth extending from the first surface into the metal article and terminating prior to the second surface. Removing the portion forms a support surface within the hole adjacent and opposite to the second surface. A metal support structure is disposed within the hole on the support surface, and a metal composition is applied into the hole and onto the metal support structure. The metal support structure, the metal composition, and the metal article are fused together.