Abstract: A preform and method for forming a structural assembly are provided. The preform can be formed by friction welding structural members to a base member and subsequently providing a connection material to join the structural members. The resulting preform can be formed with dimensions and a configuration that approximate the dimensions and configuration of the structural assembly. Thus, the structural assembly can be formed by joining multiple members that are generally smaller than the finished assembly.

Abstract: A preform and method for forming preforms and structural members are provided. The preform can be formed by cold spraying a structural material onto a base member, such that the preform has dimensions approximating the dimensions of the machined structural member to thereby reduce material waste and machining time when forming the structural member from the preform. In addition, the preforms can be plastically deformed to more closely correspond with the desired dimensions of the structural member. Further, hydrogen can be provided in a mixed stream of gas and structural material for spraying, and the resulting structural member can be subjected to a sub-atmospheric pressure to release hydrogen therefrom.