Abstract: A method of repairing a substrate includes the step of excavating a well in the substrate with an electrical discharge machining operation. A wire is then delivered to the well. Simultaneously, laser energy is routed to the well such that the laser energy intersects with the wire to produce a reconstruction weld in the well. A tool delivery system with an electrical discharge machining tool head and a reconstruction welding tool head is used to perform the excavation and welding operations.

Abstract: Novel cobalt-free iron-base, wear-resistant and anti-galling, hardfacing alloys are provided. These alloys are capable of being deposited on substrates by welding without preheating the substrate, thus facilitating field applications of cobalt-free alloys.

Abstract: A laser beam welding technique which can be utilized to accomplish clad welding and repair of the internal surface of a tube. The technique uses the addition of filler metal to build up the internal surface of the tube. The apparatus includes a laser energy source connected to an elongated weld head by an optical fiber. The elongated weld head is rotatable and contains a mirror canted at a forty-five (45) degree angle. The laser beam generated by the laser source enters the weld head through a rotary joint, passes through focusing lenses, and is reflected to the interior surface of the damaged tube by the canted mirror. Apparatus rotates the weld head which causes the beam to travel circumferentially around the interior of the tube. Metal fill material is fed to the location where the focused beam contacts the interior surface of the tube. The result is a smooth clad welding repair on the inside surface of the tube which restores the strength of the tube and leaves no crevices for future corrosion attack.

Abstract: A method of forming a clad weld on the interior surface of a tube includes the step of delivering a rotating filler metal wire to a selected weld location on the interior surface of the tube. The filler metal wire is synchronously rotated with a fiber optic cable which directs laser energy to the selected weld location. This results in the fusing of the filler metal wire to the interior surface of the tube to produce a clad weld within the tube.

Abstract: A laser welding apparatus for clad welding the interior surface of a tube is disclosed. The apparatus includes a rotating sleeve positionable within the tube. Located within the rotating sleeve is a fiber optic cable and a filler passage. The fiber optic cable receives laser energy from a laser. The filler passage receives filler material from a filler metal delivery system that synchronously moves with the rotating sleeve. Positioned at the end of the rotating sleeve is a welding head which includes a head aperture and a laser energy directional modification assembly. The laser energy from the fiber optic cable is transferred through the laser energy directional modification assembly and through the head aperture to a selected weld location on the interior surface of the tube. The filler metal from the filler metal delivery system is also conveyed through the head aperture and intersects with the laser energy at the selected weld location.

Abstract: A welding electrode suitable for underwater welding is manufactured from a welding rod with a flux layer thereon by forming a protective coating of a waterproofing material at least over this layer and subjecting it to a pressure at least as great as the pressure at a depth of water at which the welding electrode is intended to be used such that the waterproofing material is driven into pores and interstices of the flux to impregnate it. Waterproofing materials which do not produce organic residues at welding are preferred, such as liquid sealant with metallic aluminum powder, polyurethane, resins and epoxy-based coatings.

Abstract: Disclosed is a laser beam welding technique which can be utilized to accomplish clad welding and repair of the internal surface of a tube. The technique uses the addition of filler metal to build up the internal surface of the tube. The apparatus includes a laser energy source connected to an elongated weld head by an optical fiber. The elongated weld head is rotatable and contains a mirror canted at a forty-five (45) degree angle. The laser beam generated by the laser source enters the weld head through a rotary joint, passes through focusing lenses, and is reflected to the interior surface of the damaged tube by the canted mirror. Means are provided to rotate the weld head which causes the beam to travel circumferentially around the interior of the tube. Means are also provided to feed metal fill material to the location where the focused beam contacts the interior surface of the tube.

Abstract: A flux formulation particularly suited for underwater wet flux-cored arc welding of nickel-based and austenitic stainless steels, such as internals of reactor pressure vessels, is free of halogen-containing components and has the following composition:40-80%: Rutile, Titania (TiO.sub.2),0-30%: Zirconium oxide (ZrO.sub.2),0-10%: Silicon oxide (SiO.sub.2),0-5%: Potassium titanate (K.sub.2 O/TiO.sub.3 at ratio of 3:1).0-30%: Lithium silicate (Li.sub.2 SiO.sub.3),0-15%: Lithium carbonate (Li.sub.2 CP.sub.3),provided that the sum of the contents of lithium silicate (Li.sub.2 SiO.sub.3) and lithium carbonate (Li.sub.2 CO.sub.3) be no less than 10%.

Abstract: A method for repairing drive shafts such that the corrosion stress cracking resistance is increased. More specifically, the drive shaft is removed from the facility in which it is being utilized. After removal, the region of the shaft experiencing cracking is identified and machined to produce a groove having a flat bottom and outwardly tapered edges. Filler material to restore all material removed by machining and provide some excess material is placed in the groove and HIP bonded to the shaft. The excess material is removed from the surface of the shaft to restore the shaft to its original dimension. Due to the filler material having a lower coefficient of thermal expansion than the shaft the repair area is subject to compressive surface stresses.

Abstract: Fabrication of the test structure is functionally illustrated in FIG. 9. More specifically, the first step in the process is to machine the cavity 40 in the third body of austenitic material 42, as functionally illustrated at reference numeral 80. After the cavity 40 has been machined, the fault sample 34 is installed into the cavity by heating the third body of austenitic material 42 and cooling the fault sample 34. This process is functionally illustrated at reference numeral 82. After installation of the fault sample 34, the interface is welded to seal the junction and the combined structure HIP bonded, as functionally illustrated at Reference Numerals, 84 and 86. After bonding the test structure is machined into the desired configuration, as functionally illustrated at Reference Numeral 88.