Abstract: A method for creating metallic sandwich structures that includes providing at least two face sheets; providing at least two core sheets; orienting the core sheets relative to one another in a predetermined manner; and using indirect resistance roll brazing to join the core sheets to the face sheets to create a sandwich structure.

Abstract: A testing apparatus adapted to be placed within a laser powder bed fusion additive manufacturing device that includes a laser for generating a non-stationary laser beam and a build plane positioned at a predetermined location relative to the non-stationary laser beam.

Abstract: A method for ultrasonic welding of materials, comprising generating ultrasonic waves in a welding assembly; transmitting the generated waves along the welding assembly in a first direction; receiving the generated waves in a sonotrode, the waves entering the sonotrode while propagating along the first direction; causing the received waves within the sonotrode to propagate along a second direction, perpendicular to the first direction; and oscillating a welding surface of the sonotrode using peaks and valleys of the waves propagating in the second direction.

Abstract: An ultrasonic welding system that includes a rotary sonotrode, having a body that includes a first horizontal side having a first antinode; a second horizontal side having a second antinode; a first vertical side having a first node; a second vertical side having a second node; and a middle region, an upper region, and a lower region, wherein the length of the middle region is greater than the length of the upper region and greater than the length of the lower region; at least one ultrasonic transducer that is transversely aligned with the rotary sonotrode; and at least one input tool disposed between the rotary sonotrode and the transducer that includes a node and is an integral part of the transducer or is a component separate from the transducer, wherein the input tool is connected to the rotary sonotrode at the middle region thereof on either the first vertical side or the second vertical side, and wherein the connection point between the input tool and the sonotrode is located a predetermined distance aw

Abstract: A method 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. The method also includes the steps of validating the characteristics of the weld created between the first and second components in real-time during the welding process; modifying the welding apparatus to prepare the surface of the first component prior to welding to assure proper alignment of the first and second components; and/or physically modifying the second component to enhance the welding characteristics and durability thereof.

Abstract: A process for welding metallic sections that includes providing first and second metallic sections to be welded together, and wherein the welded rail sections will include a weld fusion zone that further includes a weld terminus at each rail section; providing thermite welding dies for use in welding the metallic sections together; covering the thermite welding dies with an oxide displacing or oxide dissolving flux added locally to the edges of the thermite welding dies that are immediately adjacent to the weld fusion zone and the metallic sections; positioning the thermite welding dies on the metallic sections in the region where the metallic sections are to be joined together; and initiating an exothermic reaction between the thermite welding dies and the metallic sections by introducing molten metal into the region where the metallic sections are to be joined together, wherein the exothermic reaction creates a weld between the metallic sections.

Abstract: A system for non-destructively characterizing laser welds that includes at least one phased array probe that includes a plurality of ultrasonic transducer elements arranged in an array at one end of the probe, wherein the transducer elements are operative to both generate ultrasonic signals and to receive reflections thereof, wherein the transducer elements are further arranged into discrete subgroups, and wherein each subgroup may be activated independently of the other subgroups and at different time intervals; a combination of materials for allowing the probe to conform to a contoured surface of a laser weld while enabling sound energy to be transferred directly into a laser weld under test conditions, wherein the combination of materials further includes a flexible membrane mounted on the end of the probe and a fluid filled chamber material disposed between the membrane and the array of ultrasonic transducer elements; and a data processor in communication with the at least one phased array probe that incl

Abstract: A method for fabricating assemblies includes providing first and second components that include ceramic, metal, or composite; positioning a multiphase joining interlayer between the first and second components, wherein the joining interlayer includes a first phase that melts at a first temperature and a second phase interspersed throughout the first phase, and wherein the second phase melts at a second temperature that is lower than the melting temperature of the first phase; and heating the joining interlayer to a temperature in the range of 725° C. to 1450° C. for a predetermined period of time to soften the first phase and melt the second phase, wherein the first phase remains in a solid or a semi-solid state, and wherein the second phase segregates to the boundaries of the first phase and transforms the joining interlayer into a substantially porosity-free adherent material that joins the first component to the second component.

Abstract: An ultrasonic welding system that includes an ultrasonic transducer configured to convert electricity to generate ultrasonic waves, wherein the waves propagate along a first direction from the transducer; and a sonotrode that includes a single-component body having nodal and anti-nodal regions, and configured to propagate ultrasonic waves received at a nodal region along a first direction; a plurality of redirecting features formed in the body and configured to cause received ultrasonic waves propagating along the first direction to propagate along a second direction, perpendicular to the first direction, upon encountering one or more of the redirecting features; wherein the body is further configured to stretch and compress along the second direction based on corresponding peaks and valleys of the waves propagating along the second direction; and at least one ultrasonic welding surface at an anti-nodal region of the body configured to oscillate based on the stretching and compressing, wherein opposing ends o

Abstract: A sonotrode that includes a sealing face; a front quarter wavelength region adjacent to the sealing face, wherein the front quarter wavelength region has been modified to increase the gain of the sonotrode; and a rear quarter wavelength region adjacent to the front quarter wavelength region, wherein the rear quarter wavelength region has been modified to create a non-uniform amplitude profile across the length of the sealing face of the sonotrode.

Abstract: An ultrasonic module for use in package sealing systems that includes a moveable front jaw; an elognated sonotrode disposed within the front jaw, wherein the sonotrode includes an elongated sealing face, and wherein the width of the sealing face is at least 12 inches (30.48 cm); a moveable rear jaw; and an anvil mounted on the rear jaw opposite the sonotrode, wherein the anvil mechanically cooperates with the sonotrode to seal a package.

Abstract: Electromagnetic and eddy current techniques for fast automated real-time and near real-time inspection and monitoring systems for high production rate joining processes. An eddy current system, array and method for the fast examination of welds to detect anomalies such as missed seam (MS) and lack of penetration (LOP) the system, array and methods capable of detecting and sizing surface and slightly subsurface flaws at various orientations in connection with at least the first and second weld pass.

Abstract: A method and apparatus for sealing films. In one embodiment the sealing device comprises a horn and an anvil. The film has a standard portion and an increased portion. Increased energy is applied to the film in the increased portion compared to the energy applied to the standard portion. Such a method allows for sealing of varying number of layers.

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 method 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 system for non-destructively characterizing laser welds that includes at least one phased array probe that includes a plurality of ultrasonic transducer elements arranged in an array at one end of the probe, wherein the transducer elements are operative to both generate ultrasonic signals and to receive reflections thereof, wherein the transducer elements are further arranged into discrete subgroups, and wherein each subgroup may be activated independently of the other subgroups and at different time intervals; a combination of materials for allowing the probe to conform to a contoured surface of a laser weld while enabling sound energy to be transferred directly into a laser weld under test conditions, wherein the combination of materials further includes a flexible membrane mounted on the end of the probe and a fluid filled chamber material disposed between the membrane and the array of ultrasonic transducer elements; and a data processor in communication with the at least one phased array probe that incl

Abstract: A method for fabricating assemblies includes providing first and second components that include ceramic, metal, or composite; positioning a multiphase joining interlayer between the first and second components, wherein the joining interlayer includes a first phase that melts at a first temperature and a second phase interspersed throughout the first phase, and wherein the second phase melts at a second temperature that is lower than the melting temperature of the first phase; and heating the joining interlayer to a temperature in the range of 725° C. to 1450° C. for a predetermined period of time to soften the first phase and melt the second phase, wherein the first phase remains in a solid or a semi-solid state, and wherein the second phase segregates to the boundaries of the first phase and transforms the joining interlayer into a substantially porosity-free adherent material that joins the first component to the second component.

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 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: An ultrasonic welding apparatus that includes a full-wave sonotrode that further includes a first horn, a first nodal region, a welding surface, a second nodal region, and a second horn; first and second bearing assemblies that support the sonotrode at the first and second nodal regions respectively, wherein each bearing assembly further includes a first bearing housing portion; a first low friction bearing disposed within the first bearing housing portion; a second bearing housing portion connected to the first bearing housing portion; and a second low friction bearing disposed within the second bearing housing portion; a first centering apparatus that exerts laterally-acting force on the horn of the full-wave sonotrode; and a second centering apparatus that exerts laterally-acting force on the second horn of the full-wave sonotrode.