Abstract: A composite rod includes an outer sleeve formed over an inner core, wherein the outer sleeve and the inner core are joined with a non-metallurgical bond that provides a tight fit therebetween. A process for forming a composite rod includes positioning a rod inside a tube to form an intermediate assembly, wherein the tube has an inside diameter that is greater than the outside diameter of the rod. The tube is then compressed around the rod to produce a non-metallurgical bond between the tube and the rod.

Abstract: A method of making cathodes includes forming a first intermediate assembly having a current wire in juxtaposition with an outer mandrel wire and a basket wire wound around the first two wires. The first intermediate assembly is wound around a central mandrel to form a second intermediate assembly. Pulses of energy are used to produce an alloy solder joint between the current wire and the basket wire at selected locations. The second intermediate assembly is cut into segments, and the mandrels are removed. This results in a cathode having a coiled current wire and a basket wire wound around the current wire, with the basket wire being bonded to the current wire by the alloy solder joints. The cathode includes a central bore that is substantially free of the alloy solder joint.