Abstract: In connection with plasma tap hole welding, in which a plasma jet (7) directed towards a workpiece (8) to be welded is generated by means of a welding current applied onto an electrode (2) and a plasma gas, the plasma jet at least partly penetrating through the workpiece (9), wherein at least one electrical conductor (10, 50, 60, 61) is arranged at the exit side (8?) of the plasma jet (7), a penetration current (I2?) being measured via the electrical conductor (10, 50, 60, 61), it is suggested that the penetration current (I2) is actively modified during the welding process.

Abstract: A method for purging air from a structure to be joined by welding by feeding a liquid cryogen to the structure. The liquid cryogen will enter the structure, warm up and enter the gaseous phase very rapidly. The gaseous cryogen will displace the air that is present in the structure out of the structure and reduce the content of oxygen in the structure to about 10 parts per million when welding can begin.

Abstract: A two-electrode arc welding device and two-electrode arc welding method are provided for performing welding with improved penetration performance using two non-consumable electrodes. In a two-electrode arc welding device, a power-supply unit outputs a straight-polarity voltage and a reverse-polarity voltage, which has a different electrical potential than the straight-polarity voltage. The straight-polarity voltage output from the power-supply unit is applied to a non-consumable electrode of a straight-polarity arc torch, whereby an arc is formed. The reverse-polarity voltage output from the power-supply unit is applied to a non-consumable electrode of a straight-polarity arc torch, whereby an arc is formed. An arc spacing distance, which is a distance between the ends of both the straight-polarity arc torch and the reverse-polarity arc torch, is set to be at least a minimum distance at which an arc will not occur therebetween (arc spacing critical distance).

Abstract: A method and apparatus for a plasma torch system having a plasma torch tip configuration that includes a nozzle, an electrode, and a control unit for controlling a composition of the shield gas flow, such that while cutting the contour the shield gas flow comprises a first shield gas composition and while cutting the hole the shield gas flow comprises a second shield gas composition.

Abstract: A method and apparatus for a plasma torch system having a plasma torch tip configuration that includes a nozzle, an electrode, and a control unit for controlling a composition of the shield gas flow, such that while cutting the contour the shield gas flow comprises a first shield gas composition and while cutting the hole the shield gas flow comprises a second shield gas composition.

Abstract: A device and method are provided for determining whether sufficient ground exists to perform processes such requiring the establishment of an electrical arc such arc welding or plasma cutting. The device is capable of fastening to at least one object placed in between a first contact surface and a second contact surface. The contact surfaces are composed of conductive material but separated by non-conductive material. The device further includes at least one light bulb coupled with an electrical circuit such that the electrical circuit coupled to the light bulb, broken only by non-conductive material separating the first contact surface and the second contact surface. A method of determining whether such sufficient ground exists by connecting an electrical circuit, coupled with a light bulb and broken only by the object, is also provided.

Abstract: An outer gas for plasma welding of the present invention is used in plasma welding of a stainless steel with use of a plasma welding torch in which an insert tip (2) is provided in the periphery of a tungsten electrode (1), a shield cap (3) is provided in the periphery of this insert tip (2), a front end part of the tungsten electrode (1) is located inside from a front end part of the insert tip (2), a center gas comprising an inert gas is allowed to flow into a gap between the tungsten electrode (1) and the insert tip (2), and the outer gas is allowed to flow into a gap between the insert tip (2) and the shield cap (3), wherein the outer gas is a mixed gas containing 0.5 to 2% by volume of a carbon dioxide gas with the balance of an inert gas.

Abstract: A method is disclosed for welding a first metal to a Ti-6246 alloy airfoil. The method consists of depositing weld metal by fusion welding and reshaping the airfoil to predetermined dimensions. A post weld heat treatment is applied to relieve residual stresses. Surface treatment such as laser shock peening introduces residual surface compressive stresses to enhance the mechanical integrity of the airfoil.

Abstract: A hybrid welding apparatus, and a system and method for welding at least two adjacent components having a large gap of approximately 3.0 millimeters that results in a full-penetration weld is provided. The welding system includes a hybrid welder having a defocused laser beam, an electric arc welder, and at least one bridge piece adjacent to one or more of the at least two adjacent components. The defocused laser beam and the electric arc welder are arranged and disposed to direct energy onto the at least two adjacent components to create a common molten pool operable to provide a full penetration weld to bridge the gap at a high constant weld speed, thereby joining the two adjacent components with a weld.

Abstract: A welding apparatus for welding a work-piece includes an energy source configured to generate a weld in a zone of the work-piece, with the work-piece characterized by a layer. The apparatus also includes a first wheel characterized by a first circumference and a first set of protrusions disposed on the first circumference, and a second wheel characterized by a second circumference and a second set of protrusions disposed on the second circumference. Each of the first and second wheels is configured to rotate relative to the work-piece, and the first and second sets of protrusions are configured to disrupt the layer as the work-piece is traversed between the first and second wheels. The energy source generates the weld in the zone of the work-piece following the disruption of the layer. A method employing the disclosed welding apparatus is also provided.

Abstract: Disclosed is a method for affixing a metal cladding to a metal base. The method includes: heating the metal cladding and a surface of the metal base with a heating device to create a molten metal pool having molten metal cladding layered upon molten metal base material in the metal base; stabilizing a temperature gradient of the molten metal pool with a laser beam directed into the molten metal pool; and cooling the molten metal pool to affix solidified cladding to the metal base.

Abstract: A welding apparatus for an induction motor includes a fixture operable to support a rotor and rotate the rotor about an axis of rotation of the motor, and a welding head supported adjacent the fixture and operable to weld conductor bars located about the surface of the rotor to the first shorting ring when the fixture supports the rotor. A controller controls the fixture to selectively rotate the rotor. The controller moves the welding head, the fixture, or both, so that the welding head is in a welding position, and causes the welding head to weld the conductor bars to the first shorting ring while remaining in the welding position, with the rotor rotating to create a substantially circular weld path along the first shorting ring. In some embodiments, the conductor bars are welded to both shorting rings simultaneously. A method of welding an induction motor is also provided.

Abstract: A plasma torch 1 used in plasma-arc welding is provided with a rod-shaped electrode 10, a first cylindrical nozzle 11 which is provided to surround the electrode 10 and which injects a plasma gas and a second cylindrical nozzle 12 which is provided to surround the first nozzle 11 and which injects a shielding gas. A second injection opening 121 of the second nozzle 12 directs in a substantially parallel direction with respect to an axial direction of the electrode 10 or in a direction being away from the electrode 10, and a plurality of groove portions inclining with respect to the axial direction of the electrode 10 are formed in an outer circumferential surface of the first nozzle 11 or an inner circumferential surface of the second nozzle 12.

Abstract: A process for joining a brass part and a silicone carbide ceramics part, comprising steps of: providing a metal part made of brass, a ceramic part made of silicone carbide ceramics, a titanium foil and a nickel foil; bring the metal part, ceramic part, titanium foil and nickel foil into contact, with the titanium and nickel foil inserted between the metal part and ceramic part; applying a pressure of about 20 MPa˜60 MPa to the parts to be joined; and simultaneously applying a pulse electric current to the parts while the pressure is applied for heating up the parts to a temperature of about 950° C. to about 1150° C. at a rate of about 50° C./min˜300° C./min, maintaining the temperature for about 20 minutes˜40 minutes.

Abstract: In the method according to the invention for connecting a sheet metal component (3) to a component (5) consisting of cast metal, the sheet metal component (3) and the component (5) are welded to one another by means of a pulse-welding method. In particular, a sheet metal pipe (3) can thereby be welded to the port (12) of a housing (13) consisting of cast metal. This advantage may be utilized for an exhaust system with an exhaust manifold (3) and an exhaust assembly, such as a turbocharger (5).

Abstract: In general, the present invention provides a method of piercing a workpiece with a plasma arc torch of the type having a plasma gas flow path for directing a plasma gas through the torch and a secondary gas flow path for directing a secondary gas through the torch. The method comprises directing a flow of shield gas along a distal end portion of the plasma arc torch to deflect metal spatter generated from the piercing, and ramping a current provided to the plasma arc torch along a profile during piercing and controlling current ramp parameters as a function of a thickness of the workpiece and an operating current level, wherein the current ramp parameters comprise a length of time, a ramp rate, a shape factor, and a modulation.

Abstract: Provided is a bimetallic tube for transport of hydrocarbon feedstocks in refinery process furnaces, and more particularly in furnace radiant coils, including: i) an outer tube layer being formed from carbon steels or low chromium steels comprising less than 15.0 wt. % Cr based on the total weight of the steel; ii) an inner tube layer being formed from an alumina forming bulk alloy including 5.0 to 10.0 wt. % of Al, 20.0 wt. % to 25.0 wt. % Cr, less than 0.4 wt. % Si, and at least 35.0 wt. % Fe with the balance being Ni, wherein the inner tube layer is formed plasma powder welding the alumina forming bulk alloy on the inner surface of the outer tube layer; and iii) an oxide layer formed on the surface of the inner tube layer, wherein the oxide layer is substantially comprised of alumina, chromia, silica, mullite, spinels, or mixtures thereof.

Abstract: Conventional welding methods have the disadvantage of producing worse welded joints at the beginning of the process than in the later course of the method. The method in question uses an initializing plate on which the welding process is begun and then once a consistent quality can be achieved for the welded joint continues onto the points for repair.

Abstract: A method and device for controlling a power source of a welding, cutting or plasma coating system is provided. The power source comprises a measuring part and a controllable clocked power part. A value correlating with a characteristic variable of the power part to be controlled is continuously measured by means of the measuring part, to obtain an electrical measured variable. The electrical measured variable is at least approximately integrated starting from a prescribed initial value over a prescribed integration time, the duration of which corresponds to one or more clock periods of the clocked power part. A measure value is continuously determined from the integration value and used to control the power part.

Abstract: The disclosure provides a method and apparatus for regulating an energy input of a pulsed arc plasma during a joining process by detecting first measurement signals for a first temporal response of emission light from an arc plasma in a first spectral range with a first photodiode, which has a sensitivity maximum at a first wavelength, detecting second measurement signals for a second temporal response of emission light from an arc plasma in a second spectral range, which is at least partially different from the first spectral range, with a second photodiode having a sensitivity maximum at a second wavelength that is different from the first wavelength, generating control signals by comparing the first measurement signals and the second measurement signals, and regulating an energy source, which is configured to provide energy in pulsed form for the arc plasma in accordance with the control signals.

Abstract: Elongate medical devices such as guidewires can be formed from a core wire and a preformed distal cap that is configured to fit over a distal end of the core wire. The distal cap can be attached using a variety of techniques. In particular, the distal cap can be attached to the core wire using laser welding.

Abstract: A plasma welding torch that can be reduced in size more than in conventional cases. When an inert gas G such as argon gas is supplied to an outer circumferential space around a non-consumable electrode 13, a portion of the inert gas G is used as plasma gas GP that forms a plasma arc PA between the non-consumable electrode 13 and a base material 2 via a plasma orifice 51. A plasma welding torch 1 moves, maintaining this state, in the direction of the arrow shown in FIG. 4. Meanwhile, a portion of the inert gas G supplied to a gas flowing part 21 is not used as the plasma gas GP but is used as shielding gas GS and is ejected onto the base material 2 ahead in the welding direction via a shielding orifice 52. The welding on the base material 2 is performed in a state where the plasma arc PA and the base material 2 are shielded from the air by this shielding gas.

Abstract: A method of welding a joint includes directing a first output from a high energy density heat source, such as a laser, against a first side of the joint. The method further includes directing a second output from an arc welding heat source, such as a gas metal arc welding torch, against a second side of the joint. The first output produces a keyhole surrounded by a molten metal pool which extends from the first side of the joint toward the second side of the joint. In some embodiments a third output from a second arc welding heat source may also be directed at the first side of the joint. A second molten metal pool produced by the arc welding heat source joins with the first molten metal pool and the third molten metal pool to form a common molten metal pool which solidifies to form the weld.

Abstract: A composition for welding or brazing aluminum comprises silicon (Si) and magnesium (Mg) along with aluminum in an alloy suitable for use in welding and brazing. The Si content may vary between approximately 4.7 and 10.9 wt %, and the Mg content may vary between approximately 0.15 wt % and 0.50 wt %. The alloy is well suited for operations in which little or no dilution from the base metal affects the Si and/or Mg content of the filler metal. The Si content promotes fluidity and avoids stress concentrations and cracking. The Mg content provides enhanced strength. Resulting joints may have a strength at least equal to that of the base metal with little or no dilution (e.g., draw of Mg). The joints may be both heat treated and artificially aged or naturally aged.

Abstract: A two-electrode arc welding device and two-electrode arc welding method are provided for performing welding with improved penetration performance using two non-consumable electrodes. In a two-electrode arc welding device 1, a power-supply unit 11 outputs a straight-polarity voltage and a reverse-polarity voltage, which has a different electrical potential than the straight-polarity voltage. The straight-polarity voltage output from the power-supply unit 11 is applied to a non-consumable electrode 41 of a straight-polarity arc torch 14, whereby an arc is formed. The reverse-polarity voltage output from the power-supply unit 11 is applied to a non-consumable electrode 41 of a straight-polarity arc torch 15, whereby an arc is formed. An arc spacing distance L1, which is a distance between the ends of both the straight-polarity arc torch 14 and the reverse-polarity arc torch 15, is set to be at least a minimum distance at which an arc will not occur therebetween (arc spacing critical distance).

Abstract: An alloy comprising about 0.5 weight percent to about 2 weight percent carbon, about 15 weight percent to about 30 weight percent chromium, about 4 weight percent to about 12 weight percent nickel, up to about 3 weight percent manganese, up to about 2.5 weight percent silicon, up to about 1 weight percent zirconium, up to about 3 weight percent molybdenum, up to about 3 weight percent tungsten, up to about 0.5 weight percent boron, up to about 0.5 weight percent impurities, and iron.

Abstract: The TIG welding methods of the present invention include generating an electric arc between an electrode and an object to weld the object, wherein a first shielding gas including an inert gas flows toward the welded object surrounding the electrode, a second shielding gas containing an oxidative gas flows toward the welded object along a periphery of the first shielding gas, and the concentration of the oxidative gas in the second shielding gas is set such that the oxygen concentration in the welded metal portion of the welded object is within a range of 70 to 220 wt. ppm.

Abstract: An outer gas for plasma welding of the present invention is used in plasma welding of a stainless steel with use of a plasma welding torch in which an insert tip (2) is provided in the periphery of a tungsten electrode (1), a shield cap (3) is provided in the periphery of this insert tip (2), a front end part of the tungsten electrode (1) is located inside from a front end part of the insert tip (2), a center gas comprising an inert gas is allowed to flow into a gap between the tungsten electrode (1) and the insert tip (2), and the outer gas is allowed to flow into a gap between the insert tip (2) and the shield cap (3), wherein the outer gas is a mixed gas containing 0.5 to 2% by volume of a carbon dioxide gas with the balance of an inert gas.

Abstract: In conventional hot wire welding, the deposition rate and temperature cannot be adjusted. A process for welding a component in which a heated welding wire is fed to the component is provided. Through the potential-free heating of the welding wire, the deposition rate and temperature may be further increased. A welding apparatus is also provided.

Abstract: In a negative electrode including a negative electrode plate, a negative electrode lead, and an alloy layer, the negative electrode plate includes a negative electrode current collector and a thin film-like negative electrode active material layer including an alloy-based negative electrode active material and being formed on a surface of the negative electrode current collector; the negative electrode lead contains at least one metal or alloy selected from the group consisting of nickel, nickel alloys, copper, and copper alloys; and the negative electrode current collector and the negative electrode lead are bonded to each other via an alloy layer. As such, in the negative electrode utilizing an alloy-based negative electrode active material, the negative electrode current collector and the negative electrode lead are bonded to each other in an efficient and secured manner, and the conductivity between the negative electrode current collector and the negative electrode lead is improved.

Abstract: A wear resistant multilayer overlay includes a first layer on at least a surface of an article, and a second layer metallurgically bonded to at least a portion of the first layer. The first layer includes a first continuous metallic matrix and at least one of first hard particles, blocky diamond particles, non-blocky diamond particles, TSP diamond, cubic boron nitride particles, and PCD compacts embedded in the first continuous metallic matrix, wherein the first hard particles are at least one of transition metal carbide particles and boron nitride particles. The second layer includes a second continuous metallic matrix and at least one of second hard particles, blocky diamond particles, non-blocky diamond particles, TSP diamond, cubic boron nitride particles, and PCD compacts, embedded in the second continuous metallic matrix, wherein the second hard particles are at least one of transition metal carbide particles and boron nitride particles. Related methods and articles of manufacture also are disclosed.

Abstract: A golf club head having a club face for hitting a ball comprises a hollow main body provided with a front opening, and a face member disposed at the front of the main body so that a front surface thereof forms at least a major part of the club face, and a rear surface thereof faces a hollow of the main body. The peripheral edge of the face member is welded to the main body so as to form a weld bead, and the width of the weld bead is changed so that a difference (wmax-wmin) between the maximum width wmax and minimum width wmin is not less than 1 mm.

Abstract: An implantable medical lead for mechanical and electrical connection to an implantable medical device. The lead has a ring electrode in connection with its distal end. This ring electrode a coil adapter made of a first conducted material mechanically and electrically connected, directly or indirectly, by spark plasma sintering to an electrode member made of a second conducting material.

Abstract: A burner design used for thermal treatment of a surface of materials is presented. The burner includes a tubular electrode, a nozzle, a removable rod-shaped electrode which are arranged to form a discharge chamber, a means for vapor generation in the form of a reservoir provided with a flange and filled with a liquid-absorbing material, an electric arc vortex stabilization element, an element for cooling the nozzle and the electrode, and current leads. The reservoir flange is made in the form of a connection fitting and is provided with a partition having a central opening in which the tubular electrode is positioned to enable the formation of a heating element including an evaporator and a vapor superheater, both separated by the partition, the evaporator is provided with grooves for discharging vapor into a collector out of an annular recess on a surface of the vapor superheater arranged outside the reservoir.

Abstract: A method of welding a component is provided. The component is welded using a preheating temperature of the component below 500° C. and above 400° C., wherein no material is added to an area to be welded.

Abstract: A method of welding a component is provided. The component is welded using a preheating temperature of the component below 550° C. and above 480° C. Further, a laser or a plasma is used for the welding, wherein a power of the laser or plasma is between 500 W and 900 W, and wherein a spot size of the laser beam has a diameter from 3 mm to 5 mm.

Abstract: An axle beam for an industrial vehicle has a beam and a boss. The beam is supported on a vehicle body. The boss is provided at opposite ends of the beam for supporting a kingpin. The beam includes at a longitudinally middle thereof a portion having a closed cross-section perpendicular to a longitudinal direction of the beam and is shaped at the portion to form a space which is surrounded by a front and rear and a top and bottom of the beam. The portion is formed by welding two members or by one tube member.

Abstract: A club head manufacture method has steps of: (a) providing a sole base, a crown cover and a striking face plate; (b) assembling a club head; (c) fore-welding the club head; (d) post-welding the club head; and (e) grinding an outer surface of the club head. When the club head is fabricated, the sole base and the crown cover are respectively mounted on the striking face plate and aligned precisely to save the fabricating time of the club head and increase fabricating accuracy. Therefore, the method can save manufacturing cost. Furthermore, it can increase the accuracy and constancy for the manufacturing processes.

Abstract: In connection with plasma tap hole welding, in which a plasma jet (7) directed towards a workpiece (8) to be welded is generated by means of a welding current applied onto an electrode (2) and a plasma gas, the plasma jet at least partly penetrating through the workpiece (9), wherein at least one electrical conductor (10, 50, 60, 61) is arranged at the exit side (8?) of the plasma jet (7), a penetration current (I2?) being measured via the electrical conductor (10, 50, 60, 61), it is suggested that the penetration current (I2) is actively modified during the welding process.

Abstract: A system and method employing a microplasma to electrically charge nano- or micro-particles in a gas phase and, subsequently, trap the charged particles within the microplasma using the microplasma's built-in electric fields are disclosed. Confinement of the particles allows their density to be increased over time such that very low concentrations of particles can be detected, e.g., by methods such as laser scattering and/or detection of the plasma-induced charge on the particles. Preferably, charge detection methods are employed when nano-particles are to be trapped and detected.

Abstract: The repair of cracks according to the state of the art comprises the fact that defects located on the inside must be worked outward in order to be able to be welded closed. The method according to the invention proposes not to work out cracks located on the inside, but to melt the crack located on the inside utilizing a flux agent.

Abstract: The invention relates to a solid-solution strengthened iron-nickel alloy with a high level of ductility and an expansion coefficient <5×10?6/K in the temperature range between room temperature and ?200° C. Said alloy consists of (in wt. %): between 0.005 and 0.05% of C; <0.02% of S; between 1 and 2% of Cr; between 35 and 38% of Ni; between 0.3 and 1.5% of Mn; <0.5% of Si; between 1.0 and 3.5% of ? Mo+W; between 0.2 and 1.0% of Ti; between 0.2 and 1.0% of Nb; <0.02% of P; and between 1.0 and 4.0% of Co; Fe constituting the remainder, in addition to production-related impurities.

Abstract: A process for plasma spot welding of surface-treated workpieces using a plasma torch comprises supplying a plasma-generating gas to the plasma torch, connecting a first terminal (?) of a current source to an electrode of the plasma torch, connecting a second terminal (+) of the current source to a workpiece, building up at least one plasma arc from the electrode of the torch toward the workpiece by applying electric current (I(t)) from the current source to an anode-cathode path between the electrode and the workpiece. The electric current (I(t)) is kept in a preprocessing current range (IV) in a phase I and, in a subsequent phase II, at a main processing current value (IH) having an the average value of which is higher than the average preprocessing current range (IV). Phase I is maintained at least until the at least partial evaporation of surface treatment layers of the workpieces in a joining zone.

Abstract: The method of forming hard facing on an engine valve comprising providing an engine valve, providing an austenitic iron-based alloy, the austenitic iron-based alloy including, by weight, about 0.25% to about 0.9% carbon, about 1.5% to about 3.5% boron, about 1% to about 2% silicon, at least 20% chromium, an amount of manganese effective to provide the iron-based alloy with an austenitic structure, and the balance including iron and incidental impurities, and welding the austenitic iron-based alloy to at least a portion of the engine valve.

Abstract: A method and associated apparatus for generating a plasma field, including: arranging the points of discharge of a plurality of electrodes into a plane, applying voltage to each electrode, providing at least one grounded electrode, and controlling the path between the electrodes and corresponding temperature of the plasma formed between the electrodes by controlling the signal and phase to the high voltage generators.

Abstract: The invention discloses a method and a production installation for producing a sub-assembly consisting of a plurality of parts joined together, in which the first part (1) and second part (2) are removed from a parts delivery site in the vicinity of a transport device and deposited oriented in position on one of a plurality of parts transport carriers of the transport device, and subsequently together with the parts transport carrier transported to an assembly station. The parts transport carrier is stopped in the assembly station in a holding position, whereupon the parts (1, 2), oriented towards one another, are moved by means of a vertical positioning device (200a, 200b) together from a transport position on the parts transport carrier into a preparation position, then positioned relative to one another, clamped and then joined to form a sub-assembly, whereupon the joined subassembly is again deposited on one of a plurality of parts transport carriers and transported away thereby.

Abstract: Process for reducing cracking in superalloy metal components by selectively growing large single grains during the casting operation at a region where fusion welding will be required.

Abstract: The object is to provide a laser processing apparatus, a laser processing temperature measuring apparatus, a laser processing method, and a laser processing temperature measuring method which can highly accurately detect the processing temperature when carrying out processing such as welding with laser light. A laser processing apparatus 1A for processing members. DR, UR to be processed by irradiating the members with laser light LB comprises a laser (semiconductor laser unit 20A) for generating the laser light LB; optical means for converging the laser light LB generated by the laser onto processing areas DA, UA; and a filter 30, disposed between the members DR, UR to be processed and the optical means, for blocking a wavelength of fluorescence generated by the optical means upon pumping with the laser light LB; wherein light having the wavelength blocked by the filter 30 is used for measuring a temperature of the processing areas DA, UA.

Abstract: A system and method for start flow approach control for a proportional valve in a plasma cutter is provided that includes a controller configured to determine a target gas pressure set point for a plasma cutting operation and determine a ramp pressure set point offset from the target gas pressure set point. The controller is also configured to apply a full-open drive signal to an air pressure-closing proportional valve and monitor a pressure of gas flow output from the air pressure-closing proportional valve via a sensing device. The controller is further configured to apply a ramping drive signal to the air pressure-closing proportional valve after the pressure of the gas flow has reached the ramp pressure set point and apply a target-pressure drive signal to the air pressure-closing proportional valve after the pressure of the gas flow has reached the target gas pressure set point.

Abstract: Embodiments of the present invention provide methods for manufacturing an even-wall rotor or stator that do not suffer from drawbacks of the prior art. Even-wall rotors or stators produced according to those methods are also provided. In one embodiment, a method for manufacturing a rotor or stator for use in a mud motor is provided. The method includes providing a vacuum chamber; providing a metal electrode at least partially disposed in the vacuum chamber; providing a mold disposed in the vacuum chamber; and melting a portion of the electrode with a direct current arc, the molten metal flowing into the mold ring.