Abstract: A device of filling metal in a through-via-hole formed in a semiconductor wafer and a method of filling metal in a through-via-hole using the same are disclosed. A device of filling metal in a through-via-hole formed in a semiconductor wafer includes a jig base comprising a jig configured to fix the wafer having the through-via-hole formed therein; a upper chamber 120 installed on the jig base; a lower chamber installed under the jig base; a heater installed in the upper chamber, the heater configured to apply heat to filling metal placed on the wafer to melt the filling metal; and a vacuum pump configured to generate pressure difference between the upper chamber and the lower chamber by the pressure of the lower chamber reduced by discharging air of the lower chamber 130 outside, only to fill the melted filling metal in the through-via-hole.

Abstract: A method for repairing gas turbine blades includes: a thickness-reduced portion removing step S101 of working a surface of a blade tip 10a into a flat surface 13 by removing a thickness-reduced portion 12 of the blade tip 10a; a build-up welding step S102 of forming a built-up portion 14 with a predetermined thickness by melting powder of a build-up material higher in ductility than a base material forming the gas turbine blade 10 by a laser beam and building up the melted powder in multiple layers on the blade tip 10a whose surface is worked into the flat surface 13; a forming step S103 of working the built-up portion 14 into the same shape as a shape that the blade tip 10a originally has before suffering a thickness loss; and a heat-treatment step S104 of removing a residual strain caused by laser welding in the build-up welding step S102.

Abstract: A method of manufacturing a component. The method includes the steps of heating a working region of a substrate with a heating means; directing a material into the working region to bring the material into a temporary molten state, and depositing said material on the substrate such that when the material solidifies it forms at least part of the component. The heating means power output, stand off, orientation, speed and direction of travel relative to the substrate are adjustable and controlled throughout the material deposition process to control the shape and/or size of the working region to thereby control the distribution and rate of heat delivery to the substrate.

Abstract: In a deposition method of forming a buildup on a single crystal or directionally solidified crystal parent material, metal deposition is performed from an extension in a preferential growth orientation of parent material crystals while forcedly cooling a portion of the parent material somewhat below a processed surface and beforehand giving a temperature gradient to the parent material so that a maximum temperature gradient is oriented along the preferential growth orientation of parent material crystals.

Abstract: Processes and methods related to processing and hot working alloy ingots are disclosed. A metallic material layer is deposited onto at least a region of a surface of an alloy ingot before hot working the alloy ingot. The processes and methods are characterized by a reduction in the incidence of surface cracking of the alloy ingot during hot working.

Abstract: A method for connecting electrical parts The method includes retaining a piece of metal within a nozzle, supplying inert gas to the nozzle, and irradiating the retained piece of metal with a light source while the supplied inert gas flows from apertures in the nozzle. The metal is melted by the light source. The method also includes ejecting the melted metal from the nozzle by the supplied inert gas onto electrical parts.

Abstract: A process for repairing one or more worn inlet ports on an interior or exterior surface of an extruder die wherein each inlet port provides an opening into an extrusion channel. The worn inlet port has a funnel shape and a diameter greater than that of the extrusion channel. The worn inlet port is repaired by placing a fused silicon oxide insert into one or more extrusion channels so that an external surface of the insert engages the interior surface of the extrusion channel, thereby forming a pocket around the insert between the circumference or perimeter of the worn inlet port and the external surface of the insert. The pocket is filled with molten metal, and the insert prevents the molten metal from entering the extrusion channel. When the molten metal hardens the inserts are removed. New inlet ports are thereby formed having the same diameter as the extrusion channels.

Abstract: A level entry bore welder that is easier to use and less expensive to purchase. It has an adjustable step feature that allows the operator to control the bead placement inside the bore of a work piece. It includes a simple remote control apparatus that adjusts the welding torch rotation speed as a function of the diameter of the bore. The remote control apparatus also permits the operator to turn the wire feed mechanism on and off. The welder is suited for bores up to 12 inches in diameter.

Abstract: A bore welding mechanism comprising a casing having spindle bushings rotationally and axially supporting a rotatable and axially translatable spindle for supporting a bore repair mechanism in alignment with a bore. The spindle has an axially extending keyway and a worm gear thread extending for at least a part of a length of the spindle. A spindle drive gear is coupled to the spindle by a drive key engaging with the keyway of the spindle so that the spindle is rotationally fixed to the spindle drive gear and axially translatable with respect to the spindle drive gear. A drive shaft extends through the casing, transversely to and offset from an axis of the spindle, and includes a drive shaft worm gear rotationally fixed to the drive shaft. The worm gear engages with the spindle drive gear to rotate the spindle drive gear and the spindle due to rotation of the drive shaft.

Abstract: A process for closing an opening in a surface of a component, and components formed thereby. The process entails forming a channel in the component surface so that the channel at least partially surrounds an opening at the component surface. An alloy is then deposited in the channel to form a crack-free deposit in the channel. A step is then machined that intersects the opening and is at least partially formed in the deposit. The step defines a recess that is at least partially surrounded by a peripheral portion of the deposit and has a surface recessed into the component surface. A cap is placed in the recess and welded to the peripheral portion of the deposit to define a weld joint that completely closes the opening. The surface of the weld joint is then machined to form a machined surface that is substantially flush with the component surface.

Abstract: A welding device includes an electrode head adapted to concurrently house an array of associated multiple, continuous-feed electrodes in a spaced apart configuration for concurrently depositing cladding material on the surface of a workpiece. The electrode head may be actuatable through a welding trajectory. The welding device may also include a welding power source adapted to provide power for simultaneously establishing a welding arc between each of the multiple, continuous-feed electrodes and the workpiece.

Abstract: In one embodiment, a system includes a welding controller configured to receive images from multiple observation points directed toward a deposition zone. The welding controller is also configured to control a parameter affecting deposition based on a differential analysis of the images.

Abstract: Methods for performing manual laser deposition are provided. In this regard, a representative method includes: directing a laser beam at a first deposit location of a substrate to re-melt: at least a portion of a first deposit of weld filler, at least a portion of a second deposit of weld filler located at a second deposit location that partially overlaps the first deposit, and at least a portion of the substrate.

Abstract: A new method of process control for fusion welding maintains a controlled weld pool size or volume, for example in some applications a substantially constant weld pool size or volume. The invention comprises a method of linking machine and process variables to the weld pool size or volume in real time, thereby enabling constant weld pool volume control. The invention further comprises a method of using thermal inverse models to rapidly process real-time data and enable models-based control of welding processes so as to implement constant weld pool volume control.

Abstract: A cutting die is formed by scanning a laser beam along a path corresponding to a blade pattern, and introducing a selected powder to build up an integral blade of high grade, and hard-to-wear material on the relatively softer die body. The final blade shape is machined or produced by EDM or milling. Further hardening by heat treatment is optional. Other heat sources and cladding materials could be used.

Abstract: The present invention provides a method of manufacturing a core shroud for a nuclear plant and a nuclear power plant structure in which a groove portion is easily assembled in the case of manufacturing the core shroud having a weld structure of a nuclear power plant by a laser welding, and it is possible to obtain a weld joint portion in which a plastic distortion region and a residual stress are as small as possible, going with a solidification shrinkage of the weld portion. At a time of welding butted portions of a plurality of members constructing a core shroud, a root face is provided in the butted portion, a length of the root face is set to 25% to 95% of a thickness of the thinner one of the butted portions of a plurality of members, a narrow groove is provided in the other than the root face, and the butted portions are welded by a laser welding using a weld wire.

Abstract: A welded joint improved in fatigue strength, a steel deck using the welded joint, and a process of producing the steel deck are provided. A steel deck 3 includes a steel plate 10 having a paving surface 11 on which a pavement is placed, and stiffeners 20 welded to a lower surface 12 of the steel plate opposite the paving surface. Single bevel grooves 22 are formed at respective edges 21 of each stiffener brought into contact with the steel plate, and a weld metal 30 is deposited in each single bevel groove 22. The weld metal is a low transformation-temperature welding material whose martensitic transformation occurs in a predetermined low temperature range. The groove angle ? of the single bevel grooves 22 and welding conditions are set based on data acquired so as to obtain a fixed dilution ratio of the weld metal 30 through control of penetration rate.

Abstract: Industrial tools having an outer diameter surface protected from abrasion due to silicious materials present in the Earth's crust by a layer of a hard-facing alloy with improved crack resistance, improved wear resistance, and improved hardness are provided. Additionally, a process for applying the hard-facing alloy to the surface of the industrial tools is described.

Abstract: In a hard facing process, a core material is applied to the base material of an article, which may incorporate metal components. An additive is introduced into a molten puddle generated by the hard facing process. The additive functions to increase the wear resistant capabilities of the hard faced article. In one embodiment, the additive comprises mineral particulates, which may consist of diamond granules.

Abstract: The invention relates to a method and a device for crack-free welding, repair welding, or buildup welding of metallic materials which are susceptible to hot cracking. Objects in which its application is expedient and advantageous are all components which comprise multiphase solidification alloys having a broad solidification interval or are constructed from alloys which contain alloy elements or contamination elements which form a low-melting-point eutectic material with one or more main alloy elements and which are to be joined using fusion welding methods of high power density.

Abstract: A method is provided, which ensures reliability during manufacture and in the use environment, and allows affording erosion prevention capability in an inexpensive manner, to an erosion-susceptible portion such as turbine rotor blades. An erosion preventive section 4, comprising a lower layer (low-hardness layer) 2 of an austenitic material, and an upper layer (hard layer) 3 of a hard material, such as stellite, harder than the low-hardness layer 2, is formed by laser build-up welding on a portion, which is susceptible to erosion caused by liquid droplets and solid particles in a use environment, of a target member 1 such as a turbine rotor blade. Laser build-up welding is carried out through irradiation of a laser beam from a laser light source 6 while a welding material supply means 5 supplies an austenitic material and a hard material in the form of, for instance, a rod, powder or the like.

Abstract: A laser deposition apparatus is provided which uses a laser beam to manufacture and/or repair a work piece by depositing a material on a work piece and controlling a temperature of the work piece using a laser beam prior to, during and/or after deposition. The temperature controlling laser beam has a larger cross-sectional area than a laser beam used for deposition at the surface of the work piece.

Abstract: A process for building up a leading edge of a machine component such as a leading edge of a turbine blade for a turbocharger includes forming a molten pool along the edge of the machine component, feeding a filler material in a solid state into the molten pool and melting the filler material via heat transfer between the molten pool and the filler material. A solid layer may be formed along the leading edge by cooling the molten pool. The process is applicable to remanufacturing damaged machine components having a plurality of blades with relatively thin leading edges.

Abstract: Disclosed herein is a component in a combustion system comprising a composite, the composite comprising silicon carbide; and a refractory metal silicide comprising a phase selected from Rm5Si3, Rm5Si3C, RmSi2, and a combination thereof; wherein Rm is a refractory metal selected from molybdenum, tungsten, and a combination thereof. Also disclosed is a process for preventing slag, ash, and char buildup on a surface, comprising disposing a first surface of the composite on the surface; replacing a component comprising the surface with a component consisting of the composite; or a combination thereof.

Abstract: A process for solid state deposition of a material onto a workpiece includes the steps of providing a rod of metallic deposition material, exerting pressure at one end of the rod to move the metallic deposition material into a deposition zone, rotating the rod while the pressure is being exerted to generate frictional heat when the rod contacts a surface of the workpiece, and raising the temperature of the metallic deposition material to reduce the amount of frictional heat which needs to be generated during the rotating step and to produce a microstructure which is substantially free of porosity and which has a fine grain size.

Abstract: Disclosed is a hardfacing alloy capable of withstanding service abrasion of the order of silicious earth particles and weldable on industrial products, such as tool joints and stabilizers used in oil and gas well drilling, and other industrial products. The hardfacing alloy has a low coefficient of friction resulting from excellent metal to metal resistance and significant reduction in industrial wear on industrial products, such as casing wear. Other embodiments of the invention include tool joints having the hardbanding alloy welded to the outer cylindrical surface to its box and pin members and to stabilizer ribs on the stabilizer used in earth boring, such as boring for oil and gas, other industrial products, and methods of applying the hardfacing alloy to their surfaces.

Abstract: A preserving apparatus for preserving welded joint portions 7, 8 by deposit welding on the inner surface of the welded joint portions 7, 8, in which a nozzle 4 and a pipe 5 supported under water are joined, the apparatus having: a seal member 9 that is disposed in front and behind the welded joint portions 7, 8 to be deposit welded within the nozzle 4 and pipe 5, and serves to demarcate and form a closed operation area A within the nozzle 4 and pipe 5; water drainage means 12 for draining the inside of the operation area A demarcated and formed by the seal member 9 and obtaining a gas atmosphere therein; and welding means 13 for deposit welding on the inner surface of the welded joint portions 7, 8 within the operation area A in which the gas atmosphere has been created.

Abstract: In one embodiment the present invention includes a direct-write laser lithography system. The system includes a reel-to-reel feed system that presents a metal tape to a laser for direct patterning of the metal. The laser beam is swept laterally across the tape by a moving mirror, and is intense enough to ablate the metal but not so strong as to destroy the structural integrity of the tape. The ablated metal becomes deposited to form circuit structures on a target structure.

Abstract: Methods for repairing nickel based alloy articles such as gas turbine rotors generally includes a removing a damaged portion of the articles and laser cladding a high temperature nickel based alloy powder thereto to form a solid layer. The process can be repeated until a desired thickness is obtained. Optionally, a peening process subsequent to laser cladding can be implemented to introduce compressive stress to the solid layer formed by laser cladding.

Abstract: A plasma spray apparatus for applying a coating to an article, wherein the apparatus includes a cup shaped plasma nozzle and a main gas nozzle coaxially surrounding the exterior of the plasma nozzle forming a passage between the main gas nozzle and the plasma nozzle through which the main gas containing powder particles is caused to coaxially flow, and a converging/diverging nozzle positioned at the exit of the plasma nozzle and main gas nozzle, having an entry chamber into which the plasma gas and the main gas with powder particles entrained therein flow and combine to establish a gas mixture, the gas mixture accelerating through the extended bore of the converging/diverging nozzle to a sonic or supersonic velocity so that upon impact onto the surface of the article a cohesively bonded coating will form and build-up.

Abstract: An ion fusion formation (IFF) system and method is used to fabricate a large scale three-dimensional structure in a continuous manner from successive layers of feedstock material. The system includes a moveable positioning arm coupled to a control platform. The positioning arm includes a deposition head, including a high energy beam and a feedstock feed mechanism mounted thereto. The deposition head is positioned relative to a targeted region by positioning and repositioning the moveable positioning arm, thereby providing a means for fabricating a large scale three-dimensional structure in a continuous manner. A plurality of control components coupled to the control platform are programmable to control the positioning arm whereby a plurality of customizable control parameters are input into the control components and provide positioning and repositioning of the positioning arm to align the deposition head relative to the predetermined targeted region.

Abstract: Methods for performing manual laser deposition are provided. In this regard, a representative method includes: directing a laser beam at a first deposit location of a substrate to re-melt: at least a portion of a first deposit of weld filler, at least a portion of a second deposit of weld filler located at a second deposit location that partially overlaps the first deposit, and at least a portion of the substrate.

Abstract: Disclosed is a hardfacing alloy capable of withstanding service abrasion of the order of silicious earth particles and weldable on industrial products, such as tool joints and stabilizers used in oil and gas well drilling, and other industrial products. The hardfacing alloy has a low coefficient of friction resulting from excellent metal to metal resistance and significant reduction in industrial wear on industrial products, such as casing wear. Other embodiments of the invention include tool joints having the hardbanding alloy welded to the outer cylindrical surface to its box and pin members and to stabilizer ribs on the stabilizer used in earth boring, such as boring for oil and gas, other industrial products, and methods of applying the hardfacing alloy to their surfaces.

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: A portable boring and welding machine includes a tool shaft adapted to mount tools for boring and welding workpieces. The shaft extends along an axis and is driven by an electric motor. The motor and the shaft are connected by a helical gearwheel and worm pair, the helical gearwheel being connectable to the tool shaft, and the worm being connected to a drive shaft of the motor itself.

Abstract: A method for applying wear resistant material to a substrate, the substrate comprised of material with a substrate coefficient of thermal expansion, the method including applying the wear resistant material to the substrate with application apparatus, the wear resistant material having a wear resistant material coefficient of thermal expansion, the substrate coefficient of thermal expansion within 15% of the wear resistant material coefficient of thermal expansion.

Abstract: A powder feed nozzle for laser welding applications including a multiple outlet nozzle tip for focusing a discharged powder stream. The multiple outlet nozzle tip disperses multiple outlet streams and includes a powder discharge outlet and at least one focus gas discharge outlet, radially spaced from the powder discharge outlet, for dispersing a powder stream and a gas stream. Powder flows from a powder source through a powder channel to discharge a powder stream. Focus gas flows through a focus gas channel angled relative to the powder channel to discharge a focus gas stream.

Abstract: A gas turbine engine (10) fan outlet guide vane (34) is manufactured by diffusion bonding titanium alloy sheet metal workpieces (52, 54) together to form an in integral structure (66). A titanium alloy is weld deposited at predetermined positions (70, 72) and in a predetermined shape to build up bosses (42, 44) at the radially outer end (40) of the hollow integral structure (68). The integral structure (66) is inflated at high temperature to form a hollow integral structure (68) of predetermined aerofoil shape. Apertures (46, 48) are drilled through the bosses (42, 44) to enable the radially outer end (40) of the fan outlet guide vane (34) to be attached to a fan casing (32) of the gas turbine engine (10).

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 method for applying wear resistant material to a substrate, the substrate comprised of material with a substrate coefficient of thermal expansion, the method including applying the wear resistant material to the substrate with application apparatus, the wear resistant material having a wear resistant material coefficient of thermal expansion, the substrate coefficient of thermal expansion within 15% of the wear resistant material coefficient of thermal expansion.

Abstract: Method for applying a wear-resistant layer comprising a nickel alloy matrix and intercalated tungsten carbides and/or vanadium carbides to a surface which is to be protected using arc welding or plasma welding.

Abstract: An improved method for welding and passivation forms a chromium oxide passivated film over the welded portion during the welding process. In a shielding step, a backshield gas, preferably argon, is flowed around the welding site. In a welding step, an arc gas, preferably argon with approximately 10% hydrogen and less than 1 ppm moisture content, is flowed through the welding head and a welded joint is formed, for example by high speed tungsten-inert gas (TIG) orbital welding. In the passivation step, a process gas, preferably argon with approximately 30-100 ppm of oxygen and less than 1 ppm moisture content, and preferably less than 1 ppb moisture content, is flowed over the welded portion to form a chromium oxide passivated film on the welded portion. The process gas is passed through a gas purifier prior to being flowed over the welded portion to maintain its moisture level at less than 1 ppb.

Abstract: A method for protecting high temperature stainless steel from coking and corrosion at elevated temperatures in corrosive environments, such as during ethylene production by pyrolysis of hydrocarbons or the reduction of oxide ores, by coating the stainless steel with a coating of MCrAlX in which M is nickel, cobalt, iron or a mixture thereof and X is yttrium, hafnium, zirconium, lanthanum or combination thereof deposited onto and metallurgically bonded to the stainless steel by plasma transferred arc deposition of atomized powder of MCrAlX. The coating has a thick, dense, continuous and smooth transition region providing an effective metallurgically bond of the coating with the stainless steel. The coating retains a relatively high aluminum content which permits generation of an adherent alumina layer on the surface, providing good resistance to high temperature oxidation together with good anti-coking and hot erosion resistance properties.

Abstract: A process for the manufacture of repair material. The repair material is ductile and readily mechanically deformed and can be used in the repair of turbine components. The process comprises providing a directionally solidified material, cold-swaging the directionally solidified material, and heat treating the cold-swaged material into the repair material. The repair material, after the steps of cold-swaging and heat treatment, comprises a microstructure that is essentially free from cracks, for repairing the turbine component. The invention also sets forth methods for repair of articles, such as turbine components, using the repair material, and a turbine component repaired using the repair material.

Abstract: A process for the manufacture of repair material. The repair material is ductile and readily mechanically deformed and can be used in the repair of turbine components. The process comprises providing a directionally solidified material, cold-swaging the directionally solidified material, and heat treating the cold-swaged material into the repair material. The repair material, after the steps of cold-swaging and heat treatment, comprises a microstructure that is essentially free from cracks, for repairing the turbine component. The invention also sets forth methods for repair of articles, such as turbine components, using the repair material, and a turbine component repaired using the repair material.

Abstract: An inner torch for the electric-arc spraying of cavities, in particular of cylinder contact surfaces. The inner torch as at least two torch tubes for heating electrodes. The electrodes are provided for melting purposes and are designed as wires which can be burned away in an electric arc. The inner torch also has a gas feed for a process gas which is provided for transporting and spraying the molten wire material in the direction of the cavity surface which is to be coated. The wires are guided towards one another, by way of the torch tubes, wherein at the outlet and in the region of the electric arc, the electric arc of the electrodes wires, which is arranged in the contact region of the wires, is arranged in the region of the flow of the discharged process has, referred as the main gas arranged transversely to the main transporting direction of the wires. Furthermore, in addition to being bent towards one another, the wires are also bent transversely to this direction.

Abstract: A process is provided for welding a nickel or cobalt based superalloy article to minimize cracking by preheating the entire weld area to a maximum ductility temperature range, maintaining such temperature during welding and solidification of the weld, raising the temperature for stress relief of the superalloy, then cooling at a rate effective to minimize gamma prime precipitation.

Abstract: The present invention concerns the use of a pre-alloyed atomised powder in combination with at least one melting electrode wire in the SAW method. The electrode wire is an unalloyed or low-alloy metal wire and the metal powder is a metal powder containing a higher percentage of alloying elements than the electrode wire.

Abstract: A process for the manufacture of repair material. The repair material is ductile and readily mechanically deformed and can be used in the repair of turbine components. The process comprises providing a directionally solidified material, cold-swaging the directionally solidified material, and heat treating the cold-swaged material into the repair material. The repair material, after the steps of cold-swaging and heat treatment, comprises a microstructure that is essentially free from cracks, for repairing the turbine component. The invention also sets forth methods for repair of articles, such as turbine components, using the repair material, and a turbine component repaired using the repair material.

Abstract: A method of aluminizing metals with a coating of aluminum or aluminides.