Abstract: Provided is a laser-weld manufacturing method. The method includes: providing a first component and a second component that are separated from one another by a gap, the gap having a depth and a width and at least one of the first component and the second component having a sacrificial edge-tab; exposing the sacrificial edge-tab to laser energy, the laser energy being sufficient to melt at least a portion of the sacrificial edge-tab; forming a melt-pool in the gap between the first component and the second component, the melt-pool including material from the melted portion of the sacrificial edge-tab; and solidifying the melt-pool to form a weld that joins the first component and the second component together.

Abstract: Methods of forming a weld joint using rotating shielding devices are disclosed. To form the weld joint, the rotating shielding device may be moved continuously along a seam formed between two structures being welded, so as to avoid having to remove the rotating shielding device during, for example, welding around corners. In this manner, disclosed methods of welding may improve efficiency of techniques such as vertical welding. During welding, rotating shielding devices may be coupled to a shielding gas supply, such that the shielding gas exits through an outlet formed in an axle of the rotating shielding device as the device is rotated and moved along the seam. The rotating shielding device may contain a plurality of partitions defining one or more chambers, the partitions and chambers being positioned between spaced-apart rotating portions, with the rotating shielding device configured to direct the shielding gas towards the weld pool during welding.

Abstract: Provided is a method for welding dissimilar types of titanium. The method utilizes a filler metal that is also dissimilar to the types of titanium being welded. The method forms welds with improved fatigue life at room and high temperatures with no loss of tensile strength compared to welds formed by conventional methods of welding titanium.

Abstract: Methods of forming a weld joint using rotating shielding devices are disclosed. To form the weld joint, the rotating shielding device may be moved continuously along a seam formed between two structures being welded, so as to avoid having to remove the rotating shielding device during, for example, welding around corners. In this manner, disclosed methods of welding may improve efficiency of techniques such as vertical welding. During welding, rotating shielding devices may be coupled to a shielding gas supply, such that the shielding gas exits through an outlet formed in an axle of the rotating shielding device as the device is rotated and moved along the seam. The rotating shielding device may contain a plurality of partitions defining one or more chambers, the partitions and chambers being positioned between spaced-apart rotating portions, with the rotating shielding device configured to direct the shielding gas towards the weld pool during welding.

Abstract: Rotating shielding devices for supplying a shielding gas to a weld pool as a weld joint is formed may be configured to be moved continuously along a seam formed between two structures being welded, so as to avoid having to remove the rotating shielding device during, for example, welding around corners. In this manner, rotating shielding devices and methods of welding may improve efficiency of welding techniques such as vertical welding. In operation, rotating shielding devices may be coupled to a supply of shielding gas, which may exit through an outlet formed in an axle of the rotating shielding device. The rotating shielding device may contain a plurality of partitions defining one or more chambers, the partitions and chambers being positioned between spaced-apart rotating portions, with the rotating shielding device configured to direct the shielding gas towards the weld pool during welding.

Abstract: Provided is a laser-weld manufacturing method. The method includes: providing a first component and a second component that are separated from one another by a gap, the gap having a depth and a width and at least one of the first component and the second component having a sacrificial edge-tab; exposing the sacrificial edge-tab to laser energy, the laser energy being sufficient to melt at least a portion of the sacrificial edge-tab; forming a melt-pool in the gap between the first component and the second component, the melt-pool including material from the melted portion of the sacrificial edge-tab; and solidifying the melt-pool to form a weld that joins the first component and the second component together.

Abstract: Rotating shielding devices for supplying a shielding gas to a weld pool as a weld joint is formed are disclosed. The rotating shielding device may be configured to be moved continuously along a seam formed between two structures being welded, so as to avoid having to remove the rotating shielding device during, for example, welding around corners. In this manner, disclosed rotating shielding devices and methods of welding may improve efficiency of welding techniques such as vertical welding. In operation, disclosed rotating shielding devices may be coupled to a supply of shielding gas, which may exit through an outlet formed in an axle of the rotating shielding device. The rotating shielding device may contain a plurality of partitions defining one or more chambers, the partitions and chambers being positioned between spaced-apart rotating portions, with the rotating shielding device configured to direct the shielding gas towards the weld pool during welding.

Abstract: A method of making an expanded metal sandwich structure includes cleaning at least two metal superplastic core sheets to remove metal oxides and residues that would interfere with diffusion bonding of the sheets. The core sheets are placed face-to-face and a gas pressure line fitting is inserted between one edge and is welded into place. The fitting has a through bore through which gas can flow under pressure from a gas pressure control system into the space between the core sheets. The core sheets are pressed together and laser welded together into a core pack along lines which will form junction lines between the core sheets when the core pack is superplastically expanded. The core pack is chemically cleaned to remove metal oxides and residues that would interfere with diffusion bonding of the core pack sheets to face sheets. Two metal face sheets having superplastic characteristics are chemically cleaned and placed over and under the core pack.

Abstract: A method of making an expanded metal sandwich structure includes cleaning at least two metal superplastic core sheets to remove metal oxides and residues that would interfere with diffusion bonding of the sheets. The core sheets are placed face-to-face and a gas pressure line fitting is inserted between one edge and is welded into place. The fitting has a through bore through which gas can flow under pressure from a gas pressure control system into the space between the core sheets. The core sheets are pressed together and laser welded together into a core pack along lines which will form junction lines between the core sheets when the core pack is superplastically expanded. The core pack is chemically cleaned to remove metal oxides and residues that would interfere with diffusion bonding of the core pack sheets to face sheets. Two metal face sheets having superplastic characteristics are chemically cleaned and placed over and under the core pack.

Abstract: A method of making an expanded metal sandwich structure includes cleaning at least two metal superplastic core sheets to remove metal oxides and residues that would interfere with diffusion bonding of the sheets. The core sheets are placed face-to-face and a gas pressure line fitting is inserted between one edge and is welded into place. The fitting has a through bore through which gas can from under pressure from a gas pressure control system into the space between the core sheets. The core sheets are pressed together and laser welded together into a core pack along lines which will form junction lines between the core sheets when the core pack is superplastically expanded. The core pack is chemically cleaned to remove metal oxides and residues that would interfere with diffusion bonding of the core pack sheets to face sheets. Two metal face sheets having superplastic characteristics are chemically cleaned and placed over and under the core pack.

Abstract: A superplastically formed, diffusion bonded sandwich structure having integral metal hardpoints, made by joining two superplastic metal core sheets together into a core pack by welding or diffusion bonding along a pattern of lines which form junction lines between the core sheets when the pack is inflated by gas pressure at superplastic temperatures. Face sheets are laid under and over the core pack and metal inserts are interposed between the face sheets and the core. All of the sheets in the pack are sealed together around an outside peripheral edge to create a gas tight envelope. The pack is heated to superplastic temperatures in a cavity in a die, and the top and bottom face sheets are diffusion bonded to top and bottom surfaces of the metal insert by application of heat and pressure from top and bottom inner surfaces of the die cavity.

Abstract: A method of making an expanded metal sandwich structure includes cleaning at least two metal superplastic core sheets to remove metal oxides and residues that would interfere with diffusion bonding of the sheets. The core sheets are placed face-to-face and a gas pressure line fitting is inserted between one edge and is welded into place. The fitting has a through bore through which gas can flow under pressure into the space between the core sheets. The core sheets are pressed together and laser welded together into a core pack along lines which will form junction lines between the core sheets when the core pack is superplastically expanded. The core pack and the two metal face sheets having superplastic characteristics are each chemically cleaned, and the face sheets are placed over and under the core pack.