Abstract: A metallic product is produced by an additive manufacturing method. A device for practicing has a controller with a stored instruction set for implementing the manufacturing of the metallic product. The metallic product is manufactured in a piece-wise or layer-wise manner on a target platform by a print head that is in two-way communication with the controller. The print head operates on a momentum transfer technique in which pulsed energy from an impulse source is used to launch pieces of metal toward the target platform, the pieces of metal bonding at the target platform to manufacture the metallic product.

Abstract: A metallic product is produced by an additive manufacturing method. A device for practicing has a controller with a stored instruction set for implementing the manufacturing of the metallic product. The metallic product is manufactured in a piece-wise or layer-wise manner on a target platform by a print head that is in two-way communication with the controller. The print head operates on a momentum transfer technique in which pulsed energy from an impulse source is used to launch pieces of metal toward the target platform, the pieces of metal bonding at the target platform to manufacture the metallic product.

Abstract: Disclosed are methods of forming an impulse weld in a stack comprising a plurality of metal layers. Also disclosed herein are welded products exhibiting lower electrical resistivity when compared to an electrical resistivity of a substantially identical reference stack that was not yet welded. Also disclosed herein are systems for making such welded products.

Abstract: A multiple spot vaporizing foil actuator weld (VFAW) system includes a target sheet layer secured relative to a stabilizing component, such that standoff components may be arranged sandwichably between the target and a flier sheet layer. An electrically insulating layer separates the flier from a vaporizing component sheet layer, which may comprise at least two vaporizing subsections configured to have less conductive material than at least three dividing subsections that separate the vaporizing subsections. The geometry and/or other features of the vaporizing subsections may be varied to optimize the vaporization. A second electrically insulated stabilizing component may sandwichably secure the above components between the first stabilizing component in order to control the forces generated in the VFAW process. The method involves loading the vaporizable component sheet layer with electrons via applied voltage such that the vaporizing subsections sublimate.

Abstract: A system and method for joining dissimilar metals. In one embodiment, a method comprises providing a first metal plate, a second metal plate, and an intermediate body that is positioned between the first metal plate and the second metal plate. The first metal plate is then driven into the intermediate body, which causes at least a portion of the intermediate body to collide with the second metal plate. As a result, the material of the intermediate body joins the first metal plate to the second plate. In another embodiment, a method for joining dissimilar metals comprises providing a first metal that is not amenable to welding, a second metal that is joinable to the first metal, and an intermediate body that is not joinable to at least the first metal. The intermediate body may have at least one hole such that the first metal and the second metal are positioned over and on opposite sides of the hole(s). At least a portion of the second metal may then be driven into the hole(s) to be joined to first metal.

Abstract: Disclosed are methods of forming an impact weld between different metal parts. Also disclosed herein are welded products exhibiting high strength. Also disclosed herein are systems for making such welded products.

Abstract: Described herein are methods for and devices prepared from welding shape memory alloys. The weld produced from the present methods can approach 100% joint strength relative the ultimate tensile strength of the shape memory alloy, and are substantially free of heat affected zones and brittle intermetallics.

Abstract: A multiple spot vaporizing foil actuator weld (VFAW) system includes a target sheet layer secured relative to a stabilizing component, such that standoff components may be arranged sandwichably between the target and a flier sheet layer. An electrically insulating layer separates the flier from a vaporizing component sheet layer, which may comprise at least two vaporizing subsections configured to have less conductive material than at least three dividing subsections that separate the vaporizing subsections. The geometry and/or other features of the vaporizing subsections may be varied to optimize the vaporization. A second electrically insulated stabilizing component may sandwichably secure the above components between the first stabilizing component in order to control the forces generated in the VFAW process. The method involves loading the vaporizable component sheet layer with electrons via applied voltage such that the vaporizing subsections sublimate.

Abstract: A metallic product is produced by an additive manufacturing method. A device for practicing has a controller with a stored instruction set for implementing the manufacturing of the metallic product. The metallic product is manufactured in a piece- wise or layer-wise manner on a target platform by a print head that is in two-way communication with the controller. The print head operates on a momentum transfer technique in which pulsed energy from an impulse source is used to launch pieces of metal toward the target platform, the pieces of metal bonding at the target platform to manufacture the metallic product.

Abstract: A system and method for joining dissimilar metals. In one embodiment, a method comprises providing a first metal plate, a second metal plate, and an intermediate body that is positioned between the first metal plate and the second metal plate. The first metal plate is then driven into the intermediate body, which causes at least a portion of the intermediate body to collide with the second metal plate. As a result, the material of the intermediate body joins the first metal plate to the second plate. In another embodiment, a method for joining dissimilar metals comprises providing a first metal that is not amenable to welding, a second metal that is joinable to the first metal, and an intermediate body that is not joinable to at least the first metal. The intermediate body may have at least one hole such that the first metal and the second metal are positioned over and on opposite sides of the hole(s). At least a portion of the second metal may then be driven into the hole(s) to be joined to first metal.

Abstract: An elongate tape (10) acts as a vaporizing actuator for impulse metalworking. It has an electrically-insulative base layer (20), an electrically-conductive layer (30), and an electrically-insulative top layer (40). In it, the base layer is characterized by the length of the tape and a first width W1, as measured between a pair of side edges. The conductive layer is characterized by the length of the tape and a second width W2, as measured between a pair of side edges; and the top layer is characterized by the length of the tape and a third width W3, as measured between a pair of side edges. The layers are joined to each other to form the elongate tape with the electrically-conductive layer interposed between the electrically-insulative base and top layers.

Abstract: A system and method for joining dissimilar metals. In one embodiment, a method comprises providing a first metal plate, a second metal plate, and an intermediate body that is positioned between the first metal plate and the second metal plate. The first metal plate is then driven into the intermediate body, which causes at least a portion of the intermediate body to collide with the second metal plate. As a result, the material of the intermediate body joins the first metal plate to the second plate. In another embodiment, a method for joining dissimilar metals comprises providing a first metal that is not amenable to welding, a second metal that is joinable to the first metal, and an intermediate body that is not joinable to at least the first metal. The intermediate body may have at least one hole such that the first metal and the second metal are positioned over and on opposite sides of the hole(s). At least a portion of the second metal may then be driven into the hole(s) to be joined to first metal.

Abstract: An elongate tape (10) acts as a vaporizing actuator for impulse metalworking. It has an electrically-insulative base layer (20), an electrically-conductive layer (30), and an electrically-insulative top layer (40). In it, the base layer is characterized by the length of the tape and a first width W1, as measured between a pair of side edges. The conductive layer is characterized by the length of the tape and a second width W2, as measured between a pair of side edges; and the top layer is characterized by the length of the tape and a third width W3, as measured between a pair of side edges. The layers are joined to each other to form the elongate tape with the electrically-conductive layer interposed between the electrically-insulative base and top layers.

Abstract: A system and method for joining dissimilar metals. In one embodiment, a method comprises providing a first metal plate, a second metal plate, and an intermediate body that is positioned between the first metal plate and the second metal plate. The first metal plate is then driven into the intermediate body, which causes at least a portion of the intermediate body to collide with the second metal plate. As a result, the material of the intermediate body joins the first metal plate to the second plate. In another embodiment, a method for joining dissimilar metals comprises providing a first metal that is not amenable to welding, a second metal that is joinable to the first metal, and an intermediate body that is not joinable to at least the first metal. The intermediate body may have at least one hole such that the first metal and the second metal are positioned over and on opposite sides of the hole(s). At least a portion of the second metal may then be driven into the hole(s) to be joined to first metal.

Abstract: Electrically driven rapid vaporization of thin metallic foils is used to conduct impulse-based metal working operations such as dynamic compaction of metal powders, collision welding, embossing, shearing, shape calibration, and closed-die forming. A metal body is sheared from a metal sheet using foil actuators operating at input electrical energies from 4 kJ to 10 kJ. During the impulse shearing operation, the sheared plugs were accelerated up to velocities of 1400 m/s within a few millimeters of travel distance. The sheared plugs were used as pistons to compress milled commercially pure titanium (CP-Ti) and Ti-6AI-4V alloy (Ti-6-4) powders, both of which had tap densities of approximately 25-28%. After the process, compaction in the range of greater than 90% was observed. When compared to a quasistatic cold compaction process, a significant gain in densification with same pressures was observed.

Abstract: A method for forming a piece of a sheet metal is performed by positioning a consumable body, made of metal, proximate to the piece of the sheet metal. The consumable body is rapidly vaporized, and the gas pressure generated thereby is directed into the piece of the sheet metal. This results in acceleration of the piece of sheet metal, and it is collided into a stationary body at a velocity, generally in excess of 200 m/s. Depending upon the type of stationary body, the piece of sheet metal is deformed into a predetermined shape or is welded onto the stationary body. The vaporization is accomplished by passing a high current of electricity into the consumable body. The effect of the vaporized metal may be augmented by additional components in the consumable body.

Abstract: A method for forming a piece of a sheet metal is performed by positioning a consumable body, made of metal, proximate to the piece of the sheet metal. The consumable body is rapidly vaporized, and the gas pressure generated thereby is directed into the piece of the sheet metal. This results in acceleration of the piece of sheet metal, and it is collided into a stationary body at a velocity, generally in excess of 200 m/s. Depending upon the type of stationary body, the piece of sheet metal is deformed into a predetermined shape or is welded onto the stationary body. The vaporization is accomplished by passing a high current of electricity into the consumable body. The effect of the vaporized metal may be augmented by additional components in the consumable body.