Abstract: A heater tube is provided for use in a method of producing a diamond or cubic boron nitride (CBN) tipped cutting tool by sintering a mass of crystalline particles to a metal carbide. The heater tube has a cylindrical shape and is comprised of a plurality of windings of an expanded graphite foil which are compressed together. In the method, a heater tube assembly is formed which comprises the metal carbide substrate positioned within the heater tube and a mass of diamond or CBN particles positioned within the heater tube adjacent the substrate. The method includes simultaneously applying sufficient levels of pressure to the heater tube assembly and sufficient levels of electrical current to the heater tube assembly for a sufficient amount of time to cause sintering of the crystalline particles and bonding to the substrate to form a diamond or CBN tipped cutting tool.

Abstract: A welding electrode assembly that includes a tip member and a coupling member and has certain self-aligning features which promote proper alignment during operation. In one embodiment, the coupling member acts as a self-aligning joint or connection and generally includes a housing, a movable plunger, and a biasing element such as a spring. During operation, contact between the tip member and a work piece surface causes the plunger to lift from an opening in the housing against the urging force of the spring so that the tip member can become properly aligned with the work piece.

Abstract: A welding device for powder welding is described, which comprises a welding head for transportation of at least one welding electrode to a welding area, and a powder transportation device for transportation of powder from a container to the welding area. The powder transportation device comprises at least a first pipe which at a first end has an opening which is arranged to be placed in the container in order to transport fluxing agent from the container. The powder transportation device comprises at least a first ejector which is connected to the second end of the first pipe and which is arranged to transport powder from the container via the first pipe using pressurized gas.

Abstract: A system and method for controlling heating current for hot-wire processes in any of brazing, cladding, building up, filling, hard-facing overlaying, welding, and joining applications is provided. The system includes a high intensity energy source configured to heat at least one workpiece to create a molten puddle. The system also includes a feeder subsystem that includes a wire feeder configured to feed a filler wire to the molten puddle, a first power supply configured to supply a first current through a first length of the filler wire, and a second power supply configured to supply a second current through a second length of the filler wire. The first current and the second current provide a power sufficient to resistance-heat the filler wire to at or near a melting temperature of the filler wire, and in some embodiment, the first power supply provides more than 50% of the power.

Abstract: A method for monitoring a resistance welding process carried out on a stack of metal workpieces (1) clamped between two electrodes (2a, 2b) of a clamp (3), and a device therefor. According to the method, the electrodes (2a, 2b) are subjected to a clamping force (F) and a voltage (V(t)) enabling a current (I(t)) to flow through the stack of metal workpieces (1). The monitoring method further includes at least one step of analysing the clamping force (F) by comparison with a model from a prior learning process. The result of the analysis of each step is taken into account by a decision-making matrix to generate a correction and/or control signal intended for the welding process.

Abstract: An apparatus and method arranged to use a combination of at least electrical resistance heating and mechanical friction heating to case a base material and/or a consumable material to reach a combination of temperature and pressure sufficient to cause welding. The method and apparatus configured for the simultaneous or substantially simultaneous application of both electrical resistance heating and friction heating to achieve welding is referred to as an electrofriction process, method or apparatus. This combination of resistance and friction heating allows the heating to be more localized within a relatively small weld zone, thereby improving the efficiency of the overall process and allowing the size, weight and strength and/or the cost of the application equipment and/or associated fixtures and power supplies to be reduced while enhancing its capability for operation in confined spaces and providing satisfactory welding performance.

Abstract: Electrical resistance welding with low heat input in conjunction with applied forces effecting compressive forces in the weld are utilized to weld materials sensitive to hot cracking. An electrode coupled with a force applicator performs a low heat input resistance-type weld with triaxial compressive forces introduced in the weld to prevent or inhibit the formation of tensile induced cracks in the weld. This enables subsequent fusion welding overlying the initial weld without risk of hot cracking in the final weld.

Abstract: A method of facing a substrate comprises applying a plurality of facing bodies to a carrier in a pattern corresponding to the desired pattern of the bodies on the faced substrate. The carrier has holes positioned centrally with respect to each body. Each body has, on a contact face to be fixed to the substrate, spaced raised weld elements which serve to locate the contact face parallel to and spaced from the substrate. The carrier is applied to the substrate with the contact faces of the bodies facing the substrate and then each body is electrically welded to the substrate by applying a welding tip to the body through each hole. A gap remains between the contact face and the substrate. Finally, the bodies are brazed to the substrate and brazing material flows between the bodies and the substrate. A facing kit comprises a carrier strip with facing bodies adhered thereto, each having raised weld elements in the form of dimples or lines.