Abstract: A method of manufacturing a complex-shaped metal part, including the steps of applying a metallic sheath around a sheet metal workpiece and applying an electric current through the workpiece in the metallic sheath to heat the workpiece. The method also includes shaping the workpiece in the metallic sheath into a complex-shaped metal part while it is being heated. The shaping can be performed between two ceramic dies or using other techniques for forming complex shapes and curvatures into the workpiece. The method then may include cooling the complex-shaped metal part and removing the metallic sheath from the complex-shaped metal part. This method can allow reactive and refractory material to be safely heated without oxidation when heating/forming in air when the workpiece is sealed within a sacrificial stainless steel or nickel alloy envelope to protect the enclosed workpiece.

Abstract: A method of bonding two or more metallic components into a single piece. The bonding surfaces of the metallic components are protected from reaction with the environment. A force is applied to the metallic components to push the bonding surfaces together. Simultaneous with applying the force, an electric current is passed through the bonding surfaces to joule heat and weld the bonding surfaces together to form the single piece. The bonding surfaces may be protected by plating with a noble metal, applying a coating, shielding with a noble gas, or placing into a vacuum. A press may be used to apply the force. The force and the electric current may be sufficient to push out metal around the joint of the bonding surfaces, and at least one of the bonding surfaces may be drafted to facilitate pushing out the metal. The electric current may be pulsed to induce electroplasticity.

Abstract: A system and method for more consistent joule heating of a material blank to a desired temperature. An electrical terminal delivers a current to an end portion of the blank. The terminal has a heat sink effect which would otherwise prevent the end portion from reaching the desired temperature. An active thermal buffer element is interposed between the terminal and the end portion. The buffer element includes a first surface which abuts the end portion and a second surface which abuts the terminal. The buffer element is joule heated with the blank, and a temperature gradient is created across the buffer element such that the first surface is at the desired temperature and the second surface is at a lower temperature due to the heat sink effect of the terminal. The buffer element thereby compensates for the heat sink effect and allows the end portion to reach the desired temperature.

Abstract: A system and method for more consistent joule heating of a material blank to a desired temperature. An electrical terminal delivers a current to an end portion of the blank. The terminal has a heat sink effect which would otherwise prevent the end portion from reaching the desired temperature. An active thermal buffer element is interposed between the terminal and the end portion. The buffer element includes a first surface which abuts the end portion and a second surface which abuts the terminal. The buffer element is joule heated with the blank, and a temperature gradient is created across the buffer element such that the first surface is at the desired temperature and the second surface is at a lower temperature due to the heat sink effect of the terminal. The buffer element thereby compensates for the heat sink effect and allows the end portion to reach the desired temperature.