Abstract: A welding process involves a fixture for holding a workpiece and a welder, or welding electrode. The fixture imposes ultrasonic vibration on the workpiece. The welder vibrates during vibration, and is operable at a first voltage for welding and a second voltage for peening. The peening may occur while the weldmetal is crystallizing. The welding process may be a process of welding two part as together, or of filling a groove or other feature, or of applying or restoring a surface, or of applying a hard facing or ceramic to a parent metal or object. The weldmetal may be the same, or substantially the same, as the parent metal, or it may be different. The different material may be a ceramic material.

Abstract: A welding electrode apparatus may be mounted to a robot that presents it to a workpiece along a pre-programmed path conforming to the surface of the workpiece. The welding electrode apparatus has a first drive for rotating the welding electrode about its own axis. The electrode handle has a second rotating drive having an imbalance to impose vibration on the welding rod transverse to the axis of the rod. The first drive may turn relatively slowly; the second drive may turn more quickly. The first drive has an electrical pickup by which to carry DC power to the electrode. The two rotating drives impose two frequencies of vibration into the apparatus, causing a make-and-break contact for low power spark deposition, while at the same time causing the electrode to bounce and impact the surface. The forward end of the apparatus may include a cowling and a delivery line to provide shielding gas to the electrode.

Abstract: A welded assembly includes a first object or substrate, an interlayer, and a subsequent layer deposited on the interlayer. The interlayer is an ESD coating deposited on the first object, and the subsequent layer is deposited by ESD on the interlayer. The subsequent layer is made of a different materials from the substrate. Both the interlayer and the subsequent layer are subject to peening. In one case the interlayer has a lower either a lower thermal conductivity or a lower electrical conductivity than the substrate and the subsequent layer. In another example, the subsequent layer has a cermet content of greater than 40% by wt.

Abstract: A welding electrode apparatus may be mounted to a robot that presents it to a workpiece along a pre-programmed path conforming to the surface of the workpiece. The welding electrode apparatus has a first drive for rotating the welding electrode about its own axis. The electrode handle has a second rotating drive having an imbalance to impose vibration on the welding rod transverse to the axis of the rod. The first drive may turn relatively slowly; the second drive may turn more quickly. The first drive has an electrical pickup by which to carry DC power to the electrode. The two rotating drives impose two frequencies of vibration into the apparatus, causing a make-and-break contact for low power spark deposition, while at the same time causing the electrode to bounce and impact the surface. The forward end of the apparatus may include a cowling and a delivery line to provide shielding gas to the electrode.

Abstract: A welding electrode apparatus has a base member and a locking ring for clamping a consumable electrode tip to the electrode base. The base and the tip are predominantly made of copper, or a copper alloy. The base member has a first end that is threaded to fit a welding head that supplies electric current; and an electrically conductive second end to which the electrode tip is mounted. The second portion has an externally facing, axially extending cylindrical wall. A circumferential groove is formed in the wall. The locking ring has a quick-disconnect feature in the form of an array of spring-loaded detents that deflect to release the cylindrical wall of the first member, and that spring inwardly to seat in the circumferential groove.

Abstract: A welding electrode apparatus has a base member and a locking ring for clamping a consumable electrode tip to the electrode base. The base and the tip are predominantly made of copper, or a copper alloy. The base member has a first end that is threaded to fit a welding head that supplies electric current; and an electrically conductive second end to which the electrode tip is mounted. The second portion has an externally facing, axially extending cylindrical wall. A circumferential groove is formed in the wall. The locking ring has a quick-disconnect feature in the form of an array of spring-loaded stainless steel ball bearing detents that deflect to ride upon the cylindrical wall, and spring inwardly to seat in the circumferential groove.

Abstract: A glove box has an enclosure having a glass window top and gloves mounted to the front wall. The enclosure can be tilted to so that one or other, or both, of the work piece and the window can be placed at an angle such as may facilitate processing. The glove box has an environmental control system to both to permit flushing with inert or other desired gases, and to permit heating or cooling. The workstand may have cooling passages as well. Controls are mounted inside the enclosure chamber to permit the operator to change working parameters without removing his or her hands from the gloves. A parameter status display may be located outside the enclosure. The window may be provided with a movable smoked glass filter for use during welding. The workstand may be independently adjustable for angle within the enclosure. The glove box has electrical and cooling service penetrations to permit use of a welding electrode.

Abstract: A welding rod assembly has a seat, a chuck, and a welding rod. The chuck has a socket for the welding rod. The seat has a passageway having an inlet and an outlet, and a fluid conduit through the seat. The apparatus that has a power supply having a main control unit, and a welding electrode. It has synthetic discharge signal generator programmed to produce DC discharges as output electrical signals from said power supply. Each discharge has a voltage, charge, starting time and polarity. The discharges defines a synthetic AC output. It has an output polarity reversing switch. The apparatus includes three output terminals, a first of said output terminals being connected to said welding electrode, a second of said output terminals and a third of said output terminals having respective workpiece connections.

Abstract: A welding ground apparatus comprising at least two members, the at least two members engaged and having at least one angular degree of freedom between them, the grounding apparatus including a biasing member for applying a force to at least one of the at least two members when compressed, the line of action of the force traversing a contact footprint, the contact footprint having a footprint periphery and defined by one of the at least two members.

Abstract: A welding process involves a fixture for holding a workpiece and a welder, or welding electrode. The fixture imposes ultrasonic vibration on the workpiece. The welder vibrates during vibration, and is operable at a first voltage for elding and a second voltage for peening. The peening may occur while the weldmetal is crystallizing. The welding process may be a process of welding two part as together, or of filling a groove or other feature, or of applying or restoring a surface, or of applying a hard facing or ceramic to a parent metal or object. The weldmetal may be the same, or substantially the same, as the parent metal, or it may be different. The different material may be a ceramic material.

Abstract: A welding electrode is mounted in a tool holder that is part of a handle apparatus. The handle apparatus has an electrode power connection. The handle apparatus has a housing defining a haft that can be grasped in the hand of an operator. A vibrator is mounted inside the haft. The vibrator includes a force transmitter in the form of a cantilevered beam. The cantilevered beam is electrically conductive and carries power to the tool holder. The tool holder has a handle that permits the welding rod to be rotated about its axis as it wears during deposition of welding rod material on the object work piece.

Abstract: A welding process involves a fixture for holding a workpiece and a welder, or welding electrode. The fixture imposes ultrasonic vibration on the workpiece. The welder vibrates during vibration, and is operable at a first voltage for welding and a second voltage for peening. The peening may occur while the weld metal is crystallizing. The welding process may be a process of welding two parts together, or of filling a groove or other feature, or of applying or restoring a surface, or of applying a hard facing or ceramic to a parent metal or object. The weld metal may be the same, or substantially the same, as the parent metal, or it may be different. The different material may be a ceramic material.

Abstract: A welding ground apparatus comprising at least two members, the at least two members engaged and having at least one angular degree of freedom between them, the grounding apparatus including a biasing member for applying a force to at least one of the at least two members when compressed, the line of action of the force traversing a contact footprint, the contact footprint having a footprint periphery and defined by one of the at least two members.

Abstract: A glove box has an enclosure having a glass window top and gloves mounted to the front wall. The enclosure can be tilted to so that one or other, or both, of the work piece and the window can be placed at an angle such as may facilitate processing. The glove box has an environmental control system to both to permit flushing with inert or other desired gases, and to permit heating or cooling. The workstand may have cooling passages as well. Controls are mounted inside the enclosure chamber to permit the operator to change working parameters without removing his or her hands from the gloves. A parameter status display may be located outside the enclosure. The window may be provided with a movable smoked glass filter for use during welding. The workstand may be independently adjustable for angle within the enclosure. The glove box has electrical and cooling service penetrations to permit use of a welding electrode.

Abstract: A welding electrode apparatus may be mounted to a robot that presents it to a workpiece along a pre-programmed path conforming to the surface of the workpiece. The welding electrode apparatus has a first drive for rotating the welding electrode about its own axis. The electrode handle has a second rotating drive having an imbalance to impose vibration on the welding rod transverse to the axis of the rod. The first drive may turn relatively slowly; the second drive may turn more quickly. The first drive has an electrical pickup by which to carry DC power to the electrode. The two rotating drives impose two frequencies of vibration into the apparatus, causing a make-and-break contact for low power spark deposition, while at the same time causing the electrode to bounce and impact the surface. The forward end of the apparatus may include a cowling and a delivery line to provide shielding gas to the electrode.

Abstract: A welding electrode apparatus has a base member and a locking ring for clamping a consumable electrode tip to the electrode base. The base and the tip are predominantly made of copper, or a copper alloy. The base member has a first end that is threaded to fit a welding head that supplies electric current; and an electrically conductive second end to which the electrode tip is mounted. The second portion has an externally facing, axially extending cylindrical wall. A circumferential groove is formed in the wall. The locking ring has a quick-disconnect feature in the form of an array of spring-loaded stainless steel ball bearing detents that deflect to ride upon the cylindrical wall, and spring inwardly to seat in the circumferential groove.

Abstract: A welding process involves a fixture for holding a workpiece and a welder, or welding electrode. The fixture imposes ultrasonic vibration on the workpiece. The welder vibrates during vibration, and is operable at a first voltage for welding and a second voltage for peening. The peening may occur while the weld metal is crystallizing. The welding process may be a process of welding two parts together, or of filling a groove or other feature, or of applying or restoring a surface, or of applying a hard facing or ceramic to a parent metal or object. The weld metal may be the same, or substantially the same, as the parent metal, or it may be different. The different material may be a ceramic material.

Abstract: A welding electrode is mounted in a tool holder that is part of a handle apparatus. The handle apparatus has an electrode power connection. The handle apparatus has a housing defining a haft that can be grasped in the hand of an operator. A vibrator is mounted inside the haft. The vibrator includes a force transmitter in the form of a cantilevered beam. The cantilevered beam is electrically conductive and carries power to the tool holder. The tool holder has a handle that permits the welding rod to be rotated about its axis as it wears during deposition of welding rod material on the object work piece.

Abstract: A welding process involves a fixture for holding a workpiece and a welder, or welding electrode. The fixture imposes ultrasonic vibration on the workpiece. The welder vibrates during vibration, and is operable at a first voltage for elding and a second voltage for peening. The peening may occur while the weldmetal is crystallizing. The welding process may be a process of welding two parts together, or of filling a groove or other feature, or of applying or restoring a surface, or of applying a hard facing or ceramic to a parent metal or object. The weldmetal may be the same, or substantially the same, as the parent metal, or it may be different. The different material may be a ceramic material.

Abstract: A welding process involves a fixture for holding a workpiece and a welder, or welding electrode. The fixture imposes ultrasonic vibration on the workpiece. The welder vibrates during vibration, and is operable at a first voltage for welding and a second voltage for peening. The peening may occur while the weld metal is crystallizing. The welding process may be a process of welding two parts together, or of filling a groove or other feature, or of applying or restoring a surface, or of applying a hard facing or ceramic to a parent metal or object. The weld metal may be the same, or substantially the same, as the parent metal, or it may be different. The different material may be a ceramic material.