Abstract: A protection plate is welded to a metal structure in water so that the protection plate covers the surface of the structure including a portion to be repaired. The welding is carried out such that the periphery of the protection plate is welded in water by laser welding while inactive gas is supplied to portion to be welded to seal the portion to be repaired by the protection plate. Welding is carried out while the inactive gas is supplied to the portion to be welded coaxially with a laser beam during the laser welding. The plate is provided therein with an opening in advance so as to release vapor produced from water remaining during welding between the protection plate and the structure and the opening is sealed after the periphery of the protection plate is welded to the structure.

Abstract: A method of welding the ends of two pipe sections at the open root between said spaced ends, said method comprising: selecting a metal cored welding wire having a metal sheath and a core, the wire comprising about 0.08-0.13% by weight of carbon, about 0.60-1.20% by weight manganese, and about 0.0-0.40% by weight silicon, as well as sulfur, phosphorous, chromium, nickel, molybdenum, niobium, vanadium, nitrogen, copper, and aluminum.

Abstract: The invention describes a process for producing a weld seam (1) in hardenable steel (2) having a material thickness (3) without secondary heating, comprising at least the following steps: a) positioning a welding electrode (4) with respect to a weld line (5); b) applying a voltage; c) supplying a plasma gas (6); d) forming an arc (7); e) melting the steel (2) in the vicinity of the weld line (5) over the entire material thickness (3). This process is preferably used to join components for torque transmission in motor vehicles.

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: A method of hard facing a metal substrate with a two-layer abrasion and impact resistant coating by fusing a softer inner first coat of a matrix alloy of nickel-, cobalt- or iron-base alloy with carbide particles onto the substrate and fusing a harder second outer coat of a matrix alloy of nickel-, cobalt- or iron-base alloy with angular carbide particles onto the softer inner first coat. The softer inner first coat preferably has a hardness of about 30-40 Rc and the harder outer second coat preferably has a hardness of about 50-60 Rc. The carbide particles preferably are tungsten carbide particles in the size range of about 60 to 250? and comprise about 55 to 65 wt % of each of the inner and outer coats.

Abstract: To hard-solder parts to be joined along a common joint, the parts are heated by a heat source e.g. a laser beam (3). Melted solder (7) that is stored in a container (6) is then introduced into the joint. Joints can be filled with solder in this manner at higher speed and the solidified solder surface is practically devoid of pores, thus permitting the priming or painting of said parts without the need for subsequent treatment.

Abstract: A medical implant such as a cardiac pacemaker or a defibrillator is assembled from a first element and a second element, which each have a surface. The first element and the second element are connected to one another in a joining step in the particular connection area of the first element and of the second element which forms at least a partial area of the particular surface. In a plasma activation step to be performed before the joining step, at least the connection area of the first element and/or at least the connection area of the second element is activated in a low-pressure plasma or in a plasma generated at atmospheric pressure.

Abstract: Optical Fiber Fusion Splice Device that includes a receiving mechanism, internal chamber, alignment mechanism and circuitry, and an optical welding module. The receiving mechanism is operable to receive a pair of optical fibers that have been prepared for splicing. An internal chamber serves to isolate the optical fibers from an external environment. An alignment circuitry and mechanism aligns the first optical fiber to the second optical fiber within the internal chamber, wherein a welding module optically welds or fuses the aligned optical fibers. This welding module may employ an arc between a pair of electrodes, or other device such as an Edison coil, to heat and fuse the optical fibers. The internal chamber may be coupled to an evacuation system or positive displacement system in order to evacuate or pump volatile or contaminant-containing gases from the internal chamber prior to fusing the aligned optical fibers.

Abstract: A method for imparting wear- and corrosion-resistance to a metal component comprising overlaying the component with a ductile Co-based alloy comprising between about 0.12 wt % and about 0.7 wt % C, between about 20 wt % and about 30 wt % Cr, between about 10 wt % and about 15 wt % Mo, between about 1 wt % and about 4 wt % Ni, and balance of Co, without forming cracks during the alloy's solidification.

Abstract: A method of forming a composite overlay compound on a substrate includes forming a mixture including at least one component from a first group of component materials including titanium, chrome, tungsten, vanadium, niobium, and molybdenum. The mixture also includes at least one component from a second group of component materials including carbon and boron, and the mixture further includes at least one component from a third group of component materials including silicon, nickel, and manganese. The mixture of selected component materials is then applied to a substrate material to form an overlay compound on the substrate material. The overlay compound is fused to the substrate to form a metallurgical bond between the substrate material and the overlay compound.

Abstract: A customizable ion fusion formation system and method is used to repair a targeted repair region of a workpiece with successive layers of feedstock material. The system includes a moveable positioning platform and a control platform positioned separate and apart from the moveable positioning platform. A positioning arm is mounted to the moveable positioning platform and has a deposition head, including a plasma torch and a feedstock feeder mounted thereto. The deposition head is positioned relative to the targeted repair region by positioning and repositioning the moveable positioning platform, and thus the positioning arm, thereby providing customizable repair.

Abstract: A method for manufacturing a bonded wafer with ultra-thin single crystal ferroelectric film is provided, comprising the following steps: providing a single crystal ferroelectric wafer and a carrier wafer while activating the surfaces of the single crystal ferroelectric wafer and the carrier wafer; bonding the activated surface of the single crystal ferroelectric wafer to the activated surface of the carrier wafer; and thinning the single crystal ferroelectric wafer for forming an ultra-thin single crystal ferroelectric film. Wherein, the thinning process in the aforesaid preferred embodiment is the method of polishing, grinding, chemical mechanical polishing, or etching. And the bonding force generated in the bonding process is strong enough to resist the shearing force.

Abstract: The invention relates to a method for inert gas welding or inert gas soldering of workpieces (A) made of steel, aluminum, magnesium, copper, or the alloys thereof with workpieces (B) made of steel, aluminum, magnesium, copper, or the alloys thereof by using an additional molten metal alloy, workpieces (A) and (B) being made of identical or different metals or metal alloys. The inventive method is characterized by the following steps: a) the workpieces that are to be connected are contacted edge to edge or in an overlapping manner; b) the additional metal alloy containing a Zn/Al alloy is fused; c) the additional molten metal alloy is applied to the contact points or partial areas of the contact points of the contacted workpieces; d) the connected workpieces are cooled. Steps b) and c) are carried out immediately after one another while at least steps b) and c) are carried out by using an inert gas. The invention further relates to a wire that is used in said method.

Abstract: Bucket tip tenons requiring refurbishment are removed from the bucket tips by grinding. Groups of buckets are clamped on a rotatable table in positions adjacent an induction heating coil and a robotic welding arm, respectively. While one group is preheated, the other group of buckets is in a welding location, enabling the welding head on the robotic arm to sequentially apply weld buildup material to the bucket tips. After applying weld buildup material in multiple passes and sequentially to the bucket tips, the buckets are removed, stress-relieved and the weld buildup material machined to provide refurbished tenons. Upon removal of the buckets from the table, the table is rotated to locate the preheated buckets in welding locations and additional buckets are clamped to the table for preheating.

Abstract: A customizable ion fusion formation system and method is used to repair a targeted repair region of a workpiece with successive layers of feedstock material. The system includes a moveable positioning platform and a control platform positioned separate and apart from the moveable positioning platform. A positioning arm is mounted to the moveable positioning platform and has a deposition head, including a plasma torch and a feedstock feeder mounted thereto. The deposition head is positioned relative to the targeted repair region by positioning and repositioning the moveable positioning platform, and thus the positioning arm, thereby providing customizable repair.

Abstract: Methods and apparatus for plasma-assisted joining of one or more parts together are provided. The joining process may include, for example, placing at least first and second joining areas in proximity to one another in a cavity, forming a plasma in the cavity by subjecting a gas to electromagnetic radiation in the presence of a plasma catalyst, and sustaining the plasma at least until the first and second joining areas are joined. Plasma catalysts, and methods and apparatus for igniting, modulating, and sustaining a joining plasma, are provided. Additional cavity shapes, and methods and apparatus for selective plasma-joining, are also provided.

Abstract: A method for repairing cracks in a metal part comprising the steps of providing a metal part having a crack, cleaning the crack to remove an oxide layer, depositing a repair alloy via at least one of cathodic arc deposition and low pressure plasma spraying to cover the crack, and heating the part at a temperature and pressure sufficient to close the crack.

Abstract: A plasma welding method for a golf club head includes the steps of: preparing a club head body and a striking plate, and mounting the striking plate to the club head body; moving a plasma nozzle to aim to a connection line formed between the club head body and the striking plate before the plasma welding; tilting the plasma nozzle a predetermined inclined angle with respect to a vertical direction of the combination of the club head body and the striking plate for the plasma welding; and controlling the tilted plasma nozzle to weld the striking plate to the club head body so as to constitute the golf club head.

Abstract: There is disclosed a method of applying activatable material to a member of an article of manufacture such as an automotive vehicle. According the method, the activatable material is provided to an applicator followed by applying the activatable material to the member. Preferably, the activatable material is applied in a condition that makes the material suitable for allowing further processing or assembly of the member, the article of manufacture or both.

Abstract: Disclosed herein is an automatic pulse plasma welding method and apparatus for forming a lap joint between membrane sheets, which applies plasma welding to a lap joint between membrane sheets to improve working efficiency and productivity, and which provides optimal welding conditions to the respective regions of the lap joint between membrane sheets to improve welding quality.

Abstract: A welding apparatus spot welds an upper sheet and a lower sheet together. A substantially semi-circular hole or notch is formed at an edge of the upper sheet at the desired location of spot welding. When the semi-circular hole or notch is formed, the process does not wrinkle or deform the upper sheet. A clamping cup of the welding apparatus surrounds the semi-circular hole or notch and contacts the upper surface of the upper sheet. A plasma arc torch heats the sheets, allowing entrapped vapors in a coating on the lower sheet to vent freely to the atmosphere. Filler wire is added and melted to fill the semi-circular hole or notch and to secure the overlapping sheets together.

Abstract: A method for joining weldable metal structures and compound structure formed using the method are disclosed herein. The method includes steps of abutting a first structure to a second structure along an edge to form a seam. The two structures are then welded together along the seam on one side of the structures through at least 75% of the thickness of the structures. The structures are then welded along a portion of the seam from the opposite side of the structures. The method may be used to join porous weldable metal structures. The method may be used to create a compound structure having very narrow weld seam widths.

Abstract: The invention describes a method of brazing workpieces (16) with a torch (10), in particular a plasma or welding torch, having an electrode (28), in which a transmitted and/or non-transmitted working arc supplied with power from a power source or a current source (2) is produced in order to generate a plasma beam from a delivered plasma gas, whereby at least one filler material (38) is fed to the seam region of the workpieces (16) to be joined. The filler material (38) is connected to the or to another power source or current source (39). To this end, one potential (40) of the power source or current source (39) is applied to the filler material (38) and the other potential (35, 41) to the workpieces (16). The power source or current source (39) is regulated in such a way that when the filler material (38) is lifted off the workpiece (16) an arc is prevented from being generated.

Abstract: A plasma powder welding device in this invention comprises a powder having an identical kind of main component as that of a work piece, a feeder feeding the powder to the work piece, a welding torch generating a plasma between itself and the work piece for focusing the powder fed by the feeder on the work piece and transferring the powder to the work piece, and a power source supplying an electric power to the welding torch, wherein a distance from the welding torch to a focal point to which the powder is focused is set nearly equal to or more than the height of the torch.

Abstract: The invention relates to a method and an apparatus for plasma welding. A free microwave-induced plasma jet is generated by the following steps. Microwaves are generated in a high-frequency microwave source. The microwaves are guided in a wave guide. A process gas is introduced at a pressure of p?1 bar into a microwave-transparent tube, which comprises a gas inlet opening and a gas outlet opening, the process gas being introduced through the gas inlet opening into the microwave-transparent tube in such a way that it has a tangential flow component. A plasma is generated in the microwave-transparent tube by electrodeless ignition of the process gas. The plasma jet is produced by the introduction of the plasma into a working space through a metallic expansion nozzle arranged at the gas outlet opening of the tube.

Abstract: A local environmental cell for a welding spray gun includes an annular ring having a top surface and a bottom surface, wherein the annular ring is adapted for attachment to an outer perimeter of the spray gun; and a plurality of fluid passageways radially disposed about the annular ring having a plurality of openings in the bottom surface of the ring in fluid communication with a vacuum source for providing a vacuum thereto. The use of the local environmental cell permits deposition of local bond coats as well as minimizes the number of steps associated with welding repair processes. For example, the use of the local environmental cell permits welding and formation of a low oxide bond coat during the welding process, thereby eliminating the need for placing the substrate subsequent to a welding process in a separate spray cell to deposit the bond coating.

Abstract: According to one embodiment of the invention, a method for controlling operational weld parameters of a welding-based deposition process includes generating a solid model representing a three-dimensional part on a computer, electronically slicing the solid model into a plurality of electronic two-dimensional layers, identifying a path of material deposition based on the electronic two-dimensional layers, the path comprising a plurality of deposition points, and determining a geometrical factor for each deposition point. The geometrical factor is defined by a ratio of an actual volume of material around each deposition point to a theoretical volume of material around each deposition point. The method further includes automatically adjusting, during material deposition for a respective deposition point, one or more parameters of the welding-based deposition process based on the geometrical factor for the respective deposition point.

Abstract: In a process for laser-plasma hybrid welding, to weld work pieces, a laser beam and a plasma jet are brought together in the process region close to the work piece. A free microwave-induced plasma jet is generated by the following process. Microwaves are generated in a high-frequency microwave source, and the microwaves are guided in a hollow waveguide. A process gas is introduced into a microwave-transparent tube, which includes a gas inlet opening and a gas outlet opening, at a pressure p?1 bar. The process gas is introduced into the microwave-transparent tube through the gas inlet opening in such a manner that it has a tangential flow component. A plasma is generated in the microwave-transparent tube by electrode-free ignition of the process gas, and a plasma jet is generated by introduction of the plasma into the working space through a metallic nozzle arranged at the gas outlet opening of the tube.

Abstract: A main arc ignition method capable of extending lives of a plasma electrode and a nozzle. For this purpose, before or immediately after starting arc, a plasma torch is supplied with a plasma gas at least either at a lower flow rate or at lower gas pressure; the plasma gas is switched to a gas flow rate and gas pressure of a time of cutting a work, after pilot arc is ignited between an electrode and a nozzle, or after main arc is ignited between the electrode and the work; and when generation of the main arc between the electrode and the work is detected, a pilot current is interrupted promptly by a semiconductor switch which is interposed in series with a resistance, in a pilot current circuit that is connected to the nozzle and supplies the pilot current to the pilot arc.

Abstract: A stationary shroud of a gas turbine engine made of a base metal is repaired by removing any damaged material from a flow-path region of the stationary shroud to leave an initially exposed base-metal flow-path surface; and applying a base-metal restoration overlying the initially exposed flow-path surface. The base-metal restoration is applied by furnishing a source of a structural material that is compatible with the base metal, and depositing the source of the structural material overlying the initially exposed base-metal flow-path surface of the stationary shroud by plasma transferred arc welding to form a repaired base-metal flow-path surface. An environmentally resistant rub coating may be applied overlying the base-metal restoration.

Abstract: A process produces a welded seamless PIPE having good yield strength and excellent corrosion and/or erosion resistance. Up to a maximum outside diameter corrosion and/or erosion resistant CRA PIPE is cold worked from a welded hollow, rather than using the traditional seamless pierced hollow method. A high-speed roll-forming mill is also utilized, rather than using the slow traditional break press to form the welded hollow. Welded hollow dimensions can be achieved which comply with the method of cold working's capability to produce the yield strengths and dimensional tolerances required to meet the service criteria of the PIPE's intended application.

Abstract: Methods and apparatus for plasma-assisted joining of one or more parts together are provided. The joining process may include, for example, placing at least first and second joining areas in proximity to one another in a cavity, forming a plasma in the cavity by subjecting a gas to electromagnetic radiation in the presence of a plasma catalyst, and sustaining the plasma at least until the first and second joining areas are joined. Plasma catalysts, and methods and apparatus for igniting, modulating, and sustaining a joining plasma, are provided. Additional cavity shapes, and methods and apparatus for selective plasma-joining, are also provided.

Abstract: A welding apparatus welds two or more overlapping members having a tenacious surface oxide layer. The apparatus includes a plasma arc torch operable to form a weld pool in a work piece and a weld pool disturbing device operable, in use, to disturb a weld pool formed by the plasma arc torch. The weld pool disturbing device includes a disturbing member which is movable into the weld pool. The apparatus may include a support member adapted to support the weld pool.

Abstract: A method of welding two silicon workpieces (20, 22) together into one member without the formation of cracks along the weld. A first method passes current (34, 36) through one or both of the workpieces to heat them to between 600 and 900° C. Then an electric, laser, or plasma welder (38, 40) passes along the seam (24) between the workpieces to weld them together. A second method passing current (34) through a plate (60), preferably formed of silicon, which either supports the workpieces or is brought into contact with at least one of them, whereby the workpieces are preheated prior to the welding operation.

Abstract: A hybrid welding process combining a laser beam and an electric arc, in particular a plasma arc, using special gases or gas mixtures as electric arc striking gases and shielding gases, and to its application to the welding of pipes or tubes or to the welding of tailored blanks, especially those that can be used in the automobile industry.

Abstract: A method and a device for mounting: the method characterized by comprising the steps of forming an energy wave or energy particle flow area (9) in a clearance formed between objects to be bonded having metal connection parts (4) and (5) before bonding the objects to each other, cleaning the surfaces of the metal connection parts (4) and (5) of the objects substantially simultaneously by the flowing energy wave or the energy particles, and bonding to each other the metal connection parts (4) and (5) of both objects having the surfaces activated by cleaning, whereby, basically, a chamber becomes unnecessary, the use of a large amount of special gas also becomes unnecessary, the metal connection parts (4) and (5) can be activated by efficiently cleaning out the surfaces thereof, and a bonding at a room temperature or a low temperature becomes possible.

Abstract: A plasma powder welding device in this invention comprises a powder having an identical kind of main component as that of a work piece, a feeder feeding the powder to the work piece, a welding torch generating a plasma between itself and the work piece for focusing the powder fed by the feeder on the work piece and transferring the powder to the work piece, and a power source supplying an electric power to the welding torch, wherein a distance from the welding torch to a focal point to which the powder is focused is set nearly equal to or more than the height of the torch.

Abstract: The invention relates to a plasma welding process by means of a free microwave-induced plasma jet, which is generated by means of the following process steps:

Abstract: A method and apparatus for bonding a circuit component to a circuit package or board is presented. A pressurized directional flow of plasma is applied between attachment sites of the component to be bonded and the corresponding bond pad of the package/board. During the application of plasma between the bonding surfaces, direct contact fusion/diffusion bonds the component attachment sites to the corresponding bond pads.

Abstract: Methods for applying thermal coatings on substrates using a diffusion alloyed metal powder are provided. The powder comprises pre-alloyed iron base powder particles having molybdenum particles diffusion alloyed to the base powder particles.

Abstract: A plasma processing apparatus includes a first chamber having a first wall with an inner peripheral surface and an outlet. A plurality of fluid supplying outlets are disposed along the first wall and are configured to supply a cooling fluid into the first chamber that travels in a circumferential direction around the inner peripheral surface of the first wall and in a direction towards the outlet. The cooling fluid exiting the plurality of fluid supplying outlets forms a cooling layer for cooling the inner peripheral surface of the first wall, and the outlet is configured for allowing the cooling fluid to exit therethrough while retaining the plasma within the chamber.

Abstract: Methods and apparatus for initiating a welding arc by directing a plasma jet into the space between the tip of the welding electrode and the workpiece. This is done while an electrical potential is applied between the electrode and the workpiece. The ionized plasma gas renders the space between the electrode and the workpiece more conductive, thereby reducing the voltage threshold needed to initiate an arc between the electrode and the workpiece. When the voltage threshold reaches the level of the applied electrical potential, the arc will be initiated.

Abstract: The invention relates to a method for producing shaped bodies or applying coatings on workpieces. The aim of the invention is to produce shaped bodies which are structured in an almost arbitrarily three-dimensional manner or contoured coatings are allowed to be formed on most different workpieces wherein simultaneously the required time and energy will be reduced in comparison with conventional procedures. According to the invention, a shaped body will be built-up in layers or a coating that consists of at least two individual layers will be applied on a workpiece. For this, a platform whereon the shaped body will be built-up or the workpiece is held in a clamping device which is movable within at least two axes in relation to two different sources of heat.

Abstract: A method of making a fiber optic cable termination comprises the steps of clamping an optical fiber between two spaced-apart clamps, heating the optical fiber, moving at least one of the clamps toward the other clamp to bend a first portion of the optical fiber into an S-shaped bend, wherein the S-shaped bend includes two or more bends, each having a radius of curvature of less than the diameter of the optical fiber. The step of heating the optical fiber can include the step of applying heat to the optical fiber before, during and after the step of moving at least one of the clamps toward the other clamp to bend the optical fiber or the clamps can be separated to form a tapered end on the optical fiber. A fiber optic cable termination comprising an optical fiber formed into a S-shaped bend, and/or a tapered portion is also disclosed.

Abstract: A welding apparatus spot welds two or more overlapping sheets having a coating, such as zinc coated steel or aluminum alloy with an oxide coating. A hole is formed in the upper sheet at the desired point of spot welding. A clamping cup of a plasma arc passes surrounds the hole and contacts the upper surface of the upper sheet. The torch heats the sheet, allowing entrapped vapors in the coating on the lower sheet to vent freely. Filler wire is added to fill the hole and to secure the overlapping sheets together. If the overlapping sheets are zinc coated steel, preferably the filler wire is copper based.

Abstract: Exothermic reaction mixtures are electrically ignited with a low cost foil strip of two conductive strips separated by a layer of insulation. One or more holes are formed in the ignitor to create shaped spark plasma on one side and a venting plasma on the opposite side of the hole. The spark with low energy requirements is sufficient to ignite exothermic reactions for welding, casting and other uses. The ignitor may be part of reusable crucibles and molds, or expendable packages, containers, and molds, or smaller squibs for igniting larger charges. The ignitor may be immersed in or substantially adjacent the charge of exothermic material. The spark forming hole or holes is made and shaped by a punch in a simple and low cost manner. The ignitor eliminates the need for starting powders or materials and flint gun ignitors.

Abstract: A method and apparatus for sealing a package over/around a circuit is presented. A pressurized directional flow of plasma is applied between metal bonding edges of the package and a metal surface surrounding circuitry to be enclosed in the package. During the application of plasma between the bonding surfaces, a bonding devices direct contact fusion/diffusion bonds the metal bonding edges of the package to the metal bonding surface surrounding the circuitry to be enclosed.

Abstract: Methods and apparatuses for plasma MIG welding or TIG MIG welding are disclosed. They include a plasma or TIG torch for following along a weld path by a MIG torch (or the order may be reversed). A constant distance may be maintained between the torches, and the angle of the torches, relative to the workpiece, may vary. The MIG process is performed EP or EN in various embodiments.

Abstract: The present invention provides a nonflammable ternary gas mixture to be used in a plasma machining operation. The ternary gas mixture of the present invention comprises from about 4% to about 6.2% hydrogen, 30% to 50% argon, and the balance nitrogen. In another embodiment of the present invention, a method of generating a high pressure plasma is provided. The method of this embodiment comprises introducing the ternary gas mixture of the present invention into a plasma torch apparatus, initiating a plasma in the plasma torch apparatus, and sustaining the plasma with a high voltage between a cathode and an anode.

Abstract: A method for plasma jet welding by means of a free radio frequency-induced plasma beam wherein, the rf-induced plasma beam is generated by a procedure involving a second process gas into a tube so that it has a tangential flow component and the introduction of the plasma through a metal expansion jet at the outlet.