Abstract: Indium-based interface systems, structures, and methods for forming the same are provided. The disclosed indium-based interfaces may be formed as solid structures between two solid surfaces by providing a solid indium-based material between the two surfaces, and heating the indium-based material above its melting point while in contact with each of the two surfaces to cause the indium-based material to reflow or otherwise liquefy between the two surfaces. The indium-based material may then be cooled below its melting point to form a solid interface material structure that is positioned between and in contact with each of the surfaces.

Abstract: A universal approach is described to produce welding filler materials with enhanced grain refining, for making welded objects with hot-crack resistance. Some variations provide a welding filler material comprising a functionalized metal-containing powder, wherein the functionalized metal-containing powder comprises metal or metal alloy particles and a plurality of nanoparticles disposed on surfaces of the metal or metal alloy particles, and wherein the nanoparticles are consolidated in a three-dimensional architecture throughout the welding filler material. A welded object contains a welding filler material comprising the functionalized metal-containing powder, enabling the welded object to be free of hot cracks. Other variations provide methods of making a welding filler material. This approach has been successfully demonstrated by incorporating zirconium-based nanoparticle grain refiners within a welding precursor material for welding aluminum alloy Al 7075, as one non-limiting example.

Abstract: An ultrasonic welding assembly joins bare ends of an insulated wire bundle to a wire terminal in a weldment zone by intimate contact with a sonotrode of an ultrasonic stack. A door allows the operator to place the terminal into the nest within the weldment zone. One operator hand holds the wire bundle while one contacts an external sensor. A pair of terminal clamps extend inwardly and down to secure the terminal and create a taller capture area for the loose bare wire ends. A pair of clamp finger assemblies reversibly extend towards the insulated wires away from the weldment zone for securing the wires. A wire gatherer descends upon and captures all of the wire bare ends and secures them until the horn descends, captures, and holds the wire ends in place, then extends away from the weldment zone for ultrasonic welding to commence.

Abstract: A method may include annealing a material including iron and nitrogen in the presence of an applied magnetic field to form at least one Fe16N2 phase domain. The applied magnetic field may have a strength of at least about 0.2 Tesla (T).

Abstract: A friction stir welding tool includes a rotation-symmetrical shaft having a proximal end, a distal end, and a pin, which is arranged concentrically about the rotation axis and which has a smaller diameter than the shaft at the proximal end thereof, and thus projects as compared to a shoulder region of the shaft. The shaft, at least in the shoulder region, and the pin each consists of a high-temperature-resistant metal or an alloy thereof. The pin and/or the shaft in the shoulder region consist of or are coated by a composite material, which substantially consists of molybdenum, tungsten, niobium or tantalum or an alloy of at least one of these metals, and a reinforcement phase embedded therein and consisting of at least one material having a Mohs hardness >6, a micrometer particle size, and a free enthalpy of formation at 1300 K of less than ?350 kJ/mol O2.

Abstract: A clad material includes a first layer made of stainless steel and a second layer made of Cu or a Cu alloy and roll-bonded to the first layer. In the clad material, a grain size of the second layer measured by a comparison method of JIS H 0501 is 0.150 mm or less.

Abstract: In some embodiments, a method may bond titanium to an intermediate alloy. The method may include layering a portion of an intermediate alloy onto a portion of titanium. The method may include focusing a controlled heat source on a spot of the intermediate alloy to form a weld pool in the intermediate alloy at the spot. The method may include superheating the intermediate alloy in the weld pool above the melting point of the intermediate alloy but below the melting point of titanium such that liquid intermediate alloy contacts the surface of the portion of the titanium heating the portion of the titanium. The method may include diffusing the portions of titanium and intermediate alloy together such that upon the intermediate alloy cooling below the melting point of the intermediate alloy the portions of the intermediate alloy and titanium are bonded forming a weldment.

Abstract: The method includes a step of preparing a first member made of a first metal and a second member made of a second metal having a smaller deformation resistance than the first metal, and a step of joining the first member and the second member. The step of joining includes a step of disposing the second member in a cavity of a mold, a step of heating the first member and the second member by relatively rotating the first member with respect to the second member, while pressing the first member against the second member, without changing a positional relationship, and a step of cooling the first member and the second member with the members being in contact with each other. In the step of disposing, the second member is disposed such that a second member contact surface is surrounded by the sidewall of the cavity.

Abstract: Brazing sheet for flux-free brazing, wherein an outermost surface brazing filler metal layer, consisting of an Al—Si-based alloy containing 4 to 12% Si in mass %, and an intermediate brazing filler metal layer, consisting of an Al—Si—Mg-based alloy containing 1% or more and less than 4% Si and 0.1 to 5.0% Mg in mass %, are cladded on one side or both sides of a core material, and wherein aluminum members are joined to each other without using flux in a non-oxidizing gas atmosphere under normal pressure with an oxygen concentration of 300 ppm or less, using the brazing sheets.

Abstract: A weldment that is embedded in a precast concrete building member that is used to join the concrete building member to other concrete building members. The weldment has a top plate, side plate, and outstanding top and bottom legs. The surface of the top plate and side plate are not embedded in the precast concrete building member. The legs are integrally formed with the top plate and side plate. The top plate and side plate present weldable surfaces to join by welding the precast concrete building member to another building member.

Abstract: The method for producing a metal member includes a step of preparing a first member made of a first metal and having a recessed portion formed therein, and a second member made of a second metal having a smaller deformation resistance than the first metal, and a step of joining the first member and the second member. The step of joining includes a step of increasing temperatures of the first member and the second member by relatively rotating the second member with respect to the first member while pressing the second member against the first member with at least a part of the second member being received in the recessed portion, and a step of stopping the relative rotation of the second member with respect to the first member and cooling the first member and the second member with the members being pressed against each other.

Abstract: A lead-free solder preform includes a core layer and adhesion layer coated over surfaces of the core layer, where the preform delivers the combined merits from constituent solder alloys of the core and adhesion layers to provide both high temperature performance and improved wetting in high-temperature solder applications such as die attach. The core layer may be formed of a Bi Alloy having a solidus temperature above 260° C., and the adhesion layer may be formed of Sn, a Sn alloy, a Bi alloy, In, or an In alloy having a solidus temperature below 245° C. The solder preform may be formed using techniques such as: (1) electroplating a core ribbon with an adhesion material, (2) cladding an adhesion material foil onto a core ribbon, and/or (3) dipping a core ribbon in a molten adhesion alloy bath to allow thin layers of adhesion material to adhere to a core ribbon.

Abstract: A brazing system has a first gas source, a second gas source, an enclosure, a brazing torch, and a control system configured to control a ratio of the first gas source and the second gas source.

Abstract: An additive manufacturing system includes an additive manufacturing tool configured to supply a plurality of droplets to a part, a temperature control device configured to control a temperature of the part, and a controller configured to control the composition, formation, and application of each droplet to the plurality of droplets to the part independent from control of the temperature of the part via the temperature control device. The plurality of droplets is configured to build up the part. Each droplet of the plurality of droplets includes at least one metallic anchoring material.

Abstract: A bond fixture includes a first frame defining a chamber configured to receive a leading edge of a rotor blade and a second frame pivotally coupled to the first frame. The second frame is movable between a first position and a second position. In the second position, the second frame restricts movement of the bond fixture relative to the rotor blade. At least one supporting assembly extends from the first frame towards the chamber. The at least one supporting assembly is adjustable to apply a pressure to an adjacent surface of the rotor blade.

Abstract: An interlayered structure for joining of dissimilar materials includes: a first material substrate; a second material substrate having a composition dissimilar from a composition of the first material substrate; and a plurality of interlayers disposed between the first material substrate and the second material substrate, including a first interlayer nearest to the first material substrate and a last interlayer nearest to the second material substrate. The first interlayer has a composition selected to have a maximum solid solubility within the composition of the first material substrate that is greater than or equal to the other interlayers within the composition of the first material substrate, and the last interlayer has a composition selected to have a maximum solid solubility within the composition of the second material substrate that is greater than or equal to the other interlayers within the composition of the second material substrate.

Abstract: A ribbon bonding tool including a body portion is provided. The body portion includes a tip portion. The tip portion includes a working surface between a front edge of the tip portion and a back edge of the tip portion. The working surface includes a region defining at least one of a plurality of recesses and a plurality of protrusions. The working surface also defines at least one of (a) a first planar portion between the region and the front edge of the tip portion, and (b) a second planar portion between the region and the back edge of the tip portion.

Abstract: A metallic structure defines ribs and a skin supported by the ribs. The ribs may be defined by metal strips and the skin may be attached to the ribs. Alternatively, the skin may be defined by a plurality of tiles and the ribs may be defined by flanges of each of the plurality of tiles that cooperate to define the ribs. Tiles may be attached to separate rib lattice. Structurally weak locations at nodes where ribs intersect may be reinforced. The components may be brazed together and the stiffness of adjacent locations in the structure adjusted in the brazing operation to reduce the difference in stiffness and to reduce resulting stress risers. The metallic structure may be armored using metal foam to absorb the energy of a projectile.

Abstract: A technique facilitates a welding operation in a variety of difficult environments, including downhole environments, to enable formation a dependable connection between components. A tool may be constructed to contain a material mixture used in the welding operation. The tool is conveyed to a position adjacent a weld region of components to be welded together. The material mixture is of a type which may be ignited to initiate a reaction which forms a molten metal from at least one constituent in the material mixture. Additionally, the tool comprises a nozzle oriented to direct the molten metal to the weld region so as to form a secure, welded connection between the components.

Abstract: A substantially tubular iron tip (5) that can be heated and that is extended vertically and a solder piece supply portion that supplies a first solder piece (Wh1) and a second solder piece (Wh2) in which a layer of a flux (72) is provided within a tubular solder layer in this order from above into the iron tip are provided, within the iron tip, the solder pieces are erected such that on the first solder piece, the second solder piece rides and the heat of the iron tip is used to melt the first solder piece and the second solder piece such that the molten solder is supplied downward. In this way, it is possible to more reliably heat and melt the solder pieces in a posture in which they are erected within the iron tip.