Abstract: An integrated composite structure with a graded coefficient of thermal expansion (CTE) is formed by selecting a plurality of layers of materials with a graded CTE and using joining approaches such as welding, brazing, or solid state bonding to produce a CTE-graded layered composite or near net shape. The integrated composite billet or near net shape is then processed to produce a first surface for attachment of a first structural member having a first CTE and to produce a second surface of for attachment of a second structural member having a second CTE.

Abstract: A vacuum column for oil distillation incorporates a thickened plate that has a layer of erosion-resistant material that is thicker than the corrosion-resistant thickness of an adjacent column section. Use of thickened, explosive- or roll-bonded clad plates may provide better service than either conventional plug-welded liners or conventional shell plates with weld overlays.

Abstract: A joinable, ballistic resistant product and methods of manufacturing same are disclosed, comprising at least one ballistic resistant layer; and at least one joinable layer bonded to the at least one ballistic resistant layer; wherein the at least one ballistic resistant layer is composed of a material that sufficiently resists ballistic threats at a lower areal density than comparable materials joinable to a damaged entity; and wherein the at least one joinable layer is composed of a material that is capable of sufficient joinder to the damaged entity.

Abstract: An explosion welding method for metal tube liners in which a metal tube of smaller outside diameter is positioned coaxially within a metal tube of larger inside diameter with one or more shims inserted at opposed tube ends to form a uniform annular gap. The tubes are vertically positioned on a flat surface, and the smaller tube is filled with explosive material detonated from its top surface. The detonation initiates a uniform explosive front traveling down the smaller tube expanding the internal surface of the smaller tube with sufficient velocity to weld the tubes. A vacuum may be formed within the annular gap and/or gas(es) introduced therein to prevent build-up of excessive heat at the explosive front.

Abstract: The present invention provides a device to weld metallic elements. The device is an endothermic connector that comprises a chassis that is assembled by joining two equal halves around the end of a metallic rod with an assembling nut and a pressure nut. The chassis also accommodates a metallic cable, on contact with the metallic rod's end, with an external adapter that adjusts to the chassis with a third nut. The third nut, in the cavity defined by its internal diameter, houses the inferior part of a portable unit that contains a detonator and a mixture of an explosive powder with electrolytic metal particles. The ignition of the explosive powder increases the temperature, melting the metal particles, which in liquid state, migrate to the chassis' intermediate portion, wherein, as they solidify, weld the rod's end with the cable.

Abstract: Target/backing plate constructions and methods of forming target/backing plate constructions are disclosed herein. The targets and backing plates can be bonded to one another through an appropriate interlayer. The targets can comprise one or more of titanium, tantalum, titanium zirconium, hafnium, niobium, vanadium, tungsten, copper or a combination thereof. The interlayer can comprise one or more of silver, copper, nickel, tin, titanium and indium. Target/backing plate constructions of the present invention can have bond strengths of at least 20 ksi and an average grain size within the target of less than 80 microns.

Abstract: An explosion welded article having a non-planar shape is provided. A method of preparing an apparatus for explosion welding is also provided, as is a method for forming an explosion welded article having a non-planar shape.

Abstract: A fastener device has a body member for welding and securing structural members together. The body member has a lateral bore extending between an upper flat side and a lower flat side. The sides each have a pattern of externally facing grooves communicating with the lateral bore and an exothermic material fills the patterns of grooves, the lateral bore and a radially extending bore communicating with the lateral bore. A fuse in the radial bore produces intense heat in the exothermic material to initiate an exothermic reaction to melt at least some of the body member, exothermic material, and structural members and weld the body member and structural members together. The man-portable, self-contained, reliable, fastener device permits a relatively unskilled workman to securely interconnect the structural members together at a primitive work site without requiring ancillary equipment.

Abstract: A submerged pot roll and other articles for use in galvanizing baths including a metallurgically bonded superalloy cladding layer on a steel core layer. The cladding layer improves the corrosion resistance and dross buildup of the article and improves service life while reducing costs.

Abstract: A system and method for electromagnetic surface treatment of a work piece has an electromagnetic pulse generator and an electromagnetic pulse tool. The work piece has a working surface. A current pulse generated by the electromagnetic pulse generator travels through the tool producing an electromagnetic pulse. The electromagnetic pulse interacts with the working surface causing an indentation to form. A residual compressive stress layer is also formed. The indentation has a smooth and continuous topography that is described by an indentation perimeter, an indentation transition region, an indentation sidewall, an impact transition region, and an impact region. The method may also simultaneously, or subsequently, form a second indentation which overlaps with the indentation. An inter-indentation overlap region is formed when the indentations overlap. The inter-indentation overlap region is smooth and continuous. Multiple treated surfaces may easily be formed on the working surface of the work piece.

Abstract: A magnetic welding and joining device is provided. The device has a separable induction coil that can be selectively coupled to provide an induction coil to be positioned around workpieces that are to be magnetically welded or joined.

Abstract: Reactive foils and their uses are provided as localized heat sources useful, for example, in ignition, joining and propulsion. An improved reactive foil is preferably a freestanding multilayered foil structure made up of alternating layers selected from materials that will react with one another in an exothermic and self-propagating reaction. Upon reacting, this foil supplies highly localized heat energy that may be applied, for example, to joining layers, or directly to bulk materials that are to be joined. This foil heat-source allows rapid bonding to occur at room temperature in virtually any environment (e.g., air, vacuum, water, etc.). If a joining material is used, the foil reaction will supply enough heat to melt or soften the joining material, which upon cooling will form a strong bond, joining two or more bulk materials.

Abstract: A method for manufacturing a vehicle frame assembly includes the initial steps of providing first and second structural components, disposing portions of the first and second structural components in an overlapping relationship, and generating an electromagnetic field that causes at least one of the overlapping portions of the first and second structural components to move into contact with the other of the overlapping portions of the first and second structural components at a high velocity so as to be joined together to form a joint. Third and fourth structural components are provided. The third and fourth structural components are joined to the first and second structural components together to form a vehicle frame assembly.

Abstract: Embodiments of the present invention generally relate to methods and apparatus of connecting wellbore tubulars by explosive welding, using a frangible anvil, and reforming a surface of wellbore tubulars at a connection. In one embodiment, a first tubular is aligned proximate a second tubular such that an inside diameter of the first tubular and an outside diameter of the second tubular form an annular space, a frangible anvil is disposed in a bore defined by the tubulars, and an explosive charge placed around the outside surface of the first tubular is detonated. In another embodiment, tubulars are aligned, connected by explosive welding, and then reformed at the connection.

Abstract: A method and apparatus are described for making a coldplate. A first component of, for example copper, is explosion welded to a second component of, for example aluminum. The first metal component has a top surface opposite the second metal component and at least one channel proximate the top surface adapted to carry a cooling fluid. The coldplate can be used as an interior wall for a plasma chamber.

Abstract: The invention relates to a plate heat exchanger that consists of several pieces of sheet metal that are arranged parallel to one another, that are at least partially corrugated and that form a considerable number of heat-exchange passages. A header creates a flow connection among at least some of the heat-exchange passages. At least two parts (1, 2, 3) of the plate heat exchanger consist of metallic materials that cannot be welded to one another.

Abstract: A method of attaching a balancing mass to a rotational member which has to be balanced and comprises a longitudinal axis X. The method uses magnetic pulse welding, wherein the balancing mass, at a high speed, is radially moved towards the longitudinal axis of the rotational member and, when hitting the rotational member, becomes welded thereto.

Abstract: A method of forming a sputtering target is described that involves bonding a backing plate onto a casement having one or more recesses that contain target material to form a bonded target. During the bonding process, the bonded target is optionally vacuum sealed within the recess. The bonded target is then optionally annealed while under vacuum to form an annealed sputtering target. The sputtering target can then be retrieved by removing at least a portion of the casement from the sputtering target in one or several steps. Also described is a casement having one or more recesses containing bonded target material that is optionally vacuum sealed in the casement. The casement, as well as the backing plate that is optionally bonded onto the casement, are further described as well as other options and methods.

Abstract: A coupler for joining an aluminum conduit to a steel or stainless steel conduit and which includes a main body which is formed from a first layer of aluminum and a layer of steel or an iron-chromium alloy which are explosively welded together, and wherein the main body has a first aluminum surface, and an opposite, second steel or iron-chromium alloy surface, and wherein the aluminum conduit is welded to the first aluminum surface, and the steel or stainless steel conduit is welded to the second steel or iron-chromium surface.

Abstract: A method for securing components of a vehicular driveshaft includes disposing a neck of an end fitting into the open end of a driveshaft tube. The end fitting is held with respect to the driveshaft tube so that an annular gap is formed between the neck and the driveshaft tube. An inductor is provided about the driveshaft tube adjacent the end receiving the neck. The inductor is energized to generate a magnetic field for collapsing the driveshaft tube about the neck at a high velocity so that the driveshaft tube and the end fitting are welded to each other.

Abstract: The invention encompasses a method of bonding a first mass to a second mass. A first mass of first material and a second mass of second material are provided and joined in physical contact with one another. The first and second masses are then diffusion bonded to one another simultaneously with the development of grains of the second material in the second mass. The diffusion bonding comprises solid state diffusion between the first mass and the second mass. A predominate portion of the developed grains in the second material have a maximum dimension of less than 100 microns. The invention also encompasses methods of forming a physical vapor deposition target bonded to a backing plate.

Abstract: The present invention relates to an improvement in the manufacture of metal blanks, discs, and sputtering targets by flattening only one of the two surfaces of a metal plate. The elimination of flattening the metal plate's second surface results in a significant cost reduction. The metal plate of the present invention preferably has a single-side flatness of 0.005 inches or less, which improves the reliability of the bond between the target blank and a backing plate. Preferred metals include, but are not limited to, tantalum, niobium, titanium, and alloys thereof. The present invention also relates to machining the first side of a metal plate, bonding the first side to a backing plate, and then optionally machining the second side of the metal plate.

Abstract: A method of laminating a plurality of metal plates one to another, comprising steps of (a) arranging at least first and second generally planar metal plates having exposed surfaces into a spaced apart parallel relationship with one another, (b) anchoring the spaced apart plates to a fixed location, and (c) propelling a projectile against the exposed surface of the first plate with sufficient velocity to create a spot impact between the first and second plates of sufficient energy to create a metallurgical weld between the plates at the point of projectile impact.

Abstract: A process for the manufacture of an explosively-bonded composite structure comprising a substrate, a metallic cladder and an intervening interlayer between the substrate and the cladder; the cladder and the interlayer having a waveless interface therebetween, the process comprising (A) forming a non-bonded composite structure comprising in combination, (a) a substrate having a first side; (b) an interlayer of a material compatible with the substrate, and having (i) a thickness T1; (ii) a mass M1; (iii) a first side adjacent to the substrate at a distance D1, therefrom; and (iv) a second side; (c) a cladder having (i) a thickness TC; (ii) a mass MC; (iii) a first side adjacent to the second side of the interlayer at a distance D2 therefrom; and (iv) a second side; and (d) an explosive mixture adjacent the second side of the cladder; and wherein D1 is equal to or less than 2T1; D2 is equal to or less than TC; and MC is equal to or greater than M1; and (B) detonating said explosive mixture.

Abstract: A method of forming a sputtering target is described that involves bonding a backing plate onto a casement having one or more recesses that contain target material to form a bonded target. During the bonding process, the bonded target is optionally vacuum sealed within the recess. The bonded target is then optionally annealed while under vacuum to form an annealed sputtering target. The sputtering target can then be retrieved by removing at least a portion of the casement from the sputtering target in one or several steps. Also described is a casement having one or more recesses containing bonded target material that is optionally vacuum sealed in the casement. The casement, as well as the backing plate that is optionally bonded onto the casement, are further described as well as other options and methods.

Abstract: A method for manufacturing x-ray tube parts wherein metallic pieces are explosively bonded together to establish a high strength, stable union between them. The x-ray tube parts may then be milled from the bonded metallic pieces. The explosion bonding process creates only discrete intermetallic components in the joint region instead of a continuous, weakening intermetallic layer common in brazed joints. An explosion bond joint is characterized by a wavelike interface, thereby increasing surface area over which the components are bonded and further increasing bond integrity. Rotor sleeves and other tube components may be manufactured using this method.

Abstract: A method of producing a connection between an outer joint part of a constant velocity universal joint and a shaft journal, wherein the shaft journal is provided with a flange which is co-axially attached to the outer joint part, wherein a tubular sleeve with a greater diameter is slid at a radial distance over the butt joint between the outer joint part and the flange and wherein the tubular sleeve is reduced radially by a pulse welding process and welded to the outer joint part and to the flange.

Abstract: Embodiments of the present invention generally relate to methods and apparatus of connecting wellbore tubulars by explosive welding, using a frangible anvil, and reforming a surface of wellbore tubulars at a connection. In one embodiment, a first tubular is aligned proximate a second tubular such that an inside diameter of the first tubular and an outside diameter of the second tubular form an annular space, a frangible anvil is disposed in a bore defined by the tubulars, and an explosive charge placed around the outside surface of the first tubular is detonated. In another embodiment, tubulars are aligned, connected by explosive welding, and then reformed at the connection.

Abstract: A method of laminating a plurality of metal plates one to another, comprising steps of (a) arranging at least first and second generally planar metal plates having exposed surfaces into a spaced apart parallel relationship with one another, (b) anchoring the spaced apart plates to a fixed location, and (c) propelling a projectile against the exposed surface of the first plate with sufficient velocity to create a spot impact between the first and second plates of sufficient energy to create a metallurgical weld between the plates at the point of projectile impact.

Abstract: A method for manufacturing a rotor shaft includes fabricating a first shaft portion that extends axially from a first end to a second end, fabricating a second shaft portion that extends axially from a first end to a second end, and coupling the second shaft portion to the first shaft portion with an explosive bonded joint such that the second shaft portion is aligned substantially concentrically with respect to the first shaft portion, and such that the bonded joint extends obliquely with respect to a centerline axis of symmetry of the rotor shaft.

Abstract: An apparatus for supporting a workpiece, such as a yoke having a body portion and a pair of opposed yoke arms, during a magnetic pulse welding operation includes a lower jaw, an upper jaw, and a support pin extending therebetween. During the magnetic pulse welding operation, the lower and upper jaws of the support apparatus engage the opposed yoke arms, and the support pin extends through respective openings formed through the opposed yoke arms. The support apparatus can also include a counter die that is disposed between the lower jaw and the upper jaw and has an arcuate recess formed therein that receives the outer portions of the opposed yoke arms therein. Lastly, the support apparatus can further include a pair of positioning rails that engage the body portion of the yoke. As a result, the support apparatus prevents deformation of the opposed yoke arms and absorbs shock waves that can be propagated through the yoke during the magnetic pulse welding operation.

Abstract: A magnetic pulse welding operation is performed to secure first and second metallic components together, such as a yoke and a driveshaft tube in a vehicular driveshaft assembly. The yoke includes a first portion, such as a body portion, and a second portion, such as a pair of opposed yoke arms, that are separated by a bridge portion. The end of the driveshaft tube is disposed co-axially about the body portion of the yoke, and a magnetic pulse welding operation is performed to secure the end of the driveshaft tube to the body portion of the yoke. The bridge portion can be defined by a groove formed in either the outer surface or the inner surface of the yoke. The groove may have side portions that extend either generally perpendicular or are angled or tapered relative to an axis of rotation of the yoke. If desired, a pair of opposed, semi-circular grooves may be formed in the yoke to define the bridge portion.

Abstract: A magnetic pulse welding operation is performed to secure first and second metallic components together, such as a yoke and a driveshaft tube in a vehicular driveshaft assembly. The yoke includes a first portion, such as a body portion, and a second portion, such as a pair of opposed yoke arms. The end of the driveshaft tube is disposed co-axially about the body portion of the yoke. An inductor axially is positioned co-axially about the overlapping portions of the end of the driveshaft tube and the body portion of the yoke. The inductor is energized to perform a magnetic pulse welding operation to secure the end of the driveshaft tube to the body portion of the yoke without generating a significant flow of air toward the inductor.

Abstract: A method for manufacturing x-ray tube parts, wherein metallic pieces are explosively bonded together to establish a high strength, stable union between them. The x-ray tube parts may then be milled from the bonded metallic pieces. The explosion bonding process creates only discrete intermetallic components in the joint region instead of a continuous, weakening intermetallic layer common in brazed joints. An explosion bond joint is characterized by a wavelike interface, thereby increasing surface area over which the components are bonded and further increasing bond integrity. Stems, rotor hubs, rotor sleeves, anodes, and other tube components may be manufactured using this method.

Abstract: A method for manufacturing a vehicle frame assembly includes the initial steps of providing first and second structural components, disposing portions of the first and second structural components in an overlapping relationship, and generating an electromagnetic field that causes at least one of the overlapping portions of the first and second structural components to move into contact with the other of the overlapping portions of the first and second structural components at a high velocity so as to be joined together to form a joint. Third and fourth structural components are provided. The third and fourth structural components are joined to the first and second structural components together to form a vehicle frame assembly.

Abstract: In accordance with the invention a reactive multilayer foil is fabricated by providing an assembly (stack or multilayer) of reactive layers, inserting the assembly into a jacket, deforming the jacketed assembly to reduce its cross sectional area, flattening the jacketed assembly into a sheet, and then removing the jacket. Advantageously, the assembly is wound into a cylinder before insertion into the jacket, and the jacketed assembly is cooled to a temperature below 100° C. during deforming. The resulting multilayer foil is advantageous as a freestanding reactive foil for use in bonding, ignition or propulsion.

Abstract: A method whereby a composite clad metal ingot can be produced for onward processing at higher temperatures which are sufficient to allow the properties of the substrate material to be adequately controlled to meet specific requirements. These higher temperatures are required to avoid the undue levels of work hardening which occurs at the lower temperatures previously employed because of the need to avoid the formation of deleterious intermetallics at the bonded clad substrate interface. Such intermetallics are formed at temperatures above approximately 850° C. and should they be present, will weaken or destroy the bond. The ingot, consisting of a steel or stainless steel substrate which is clad with a corrosion resistant metal, preferably of titanium, zirconium or their alloys, and containing an interlayer of high melting point metal of tantalum, niobium (columbium) or their alloys, is processed at temperatures above 900° C.

Abstract: The present invention is directed to a metal block suitable for machining, the metal block comprising at least two superimposed metal plates, each having a thickness of at least 12.5 mm, wherein the yield strength of the block is at least 75% of the yield strength of the initial metal plate(s).

Abstract: A method for manufacturing x-ray tube parts is disclosed wherein metallic pieces are explosively bonded together to establish a high strength, stable union between them. The x-ray tube parts may then be milled from the bonded metallic pieces. The explosion bonding process creates only discrete intermetallic components in the joint region instead of a continuous, weakening intermetallic layer common in brazed joints. An explosion bond joint is characterized by a wavelike interface, thereby increasing surface area over which the components are bonded and further increasing bond integrity. Stems, rotor hubs, rotor sleeves, anodes, and other tube components may be manufactured using this method.

Abstract: A target assembly for a physical vapor deposition system having a target material flux region which produces backscatter particles and a substrate support assembly is provided. In one embodiment, the target assembly comprises a central region and a flange radially extending from the central region. The flange is constructed of a first material and is adapted to support the target assembly within the physical vapor deposition system in a parallel spaced apart relation to the substrate support assembly. A flange cover member is disposed between the flange and the flux region. The flange cover member is constructed of a material having a greater adhesiveness to the backscatter particles than the first material and is permanently secured to the flange. A target member constructed of a sputterable material is disposed between the central region of the target assembly and the flux region of the physical vapor deposition system.

Abstract: A method of hydroforming a tubular structure of varying diameter along its longitudinal axis, comprising the formation of a tubular blank member by welding together, at their periphery, tubes of different diameters using electromagnetic pulse welding.

Abstract: A component for use in a vehicular driveshaft assembly includes a tube yoke formed from a first material and having a hollow cylindrical sleeve portion extending co-axially therefrom. A first end of a driveshaft tube, also formed from the first material, is disposed telescopically about the sleeve portion of the tube yoke and is secured thereto using conventional welding processes. A transition member includes a main body portion having a hollow cylindrical sleeve portion that extends co-axially therefrom. A second end of a driveshaft tube is disposed telescopically about the sleeve portion of the transition member and is secured thereto using conventional welding processes.

Abstract: In a method of manufacturing composite sheet steel of maraging steel, wherein the composite sheet steel comprises an outer layer and an inner layer, wherein the outer layer is harder than the inner layer and the inner layer is more tenacious than the outer layer, the steel of the inner layer is produced with a chemical composition containing in percent by weight: C≦0.01, Si≦0.1, Mn≦0.1, P≦0.005, S≦0.005, Cu≦0.1, Mo 4.80 to 5.20, Ni 17.5 to 18.5 , Cr≦0.1, Ti 0.55 to 0.70, Co 8.0 to 9.0; and the steel of the outer layer is produced with purification in a zone melting process with a chemical composition containing in percent by weight: C≦0.01, Si<0.1, Mn 0.02 to 0.20, P≦0.005, S≦0.005, Cu 0.01 to 0.20, Mo 4.80 to 5.20, Ni 17.5 to 18.5, Cr 0.01 to 0.20, Ti 1.80 to 1.95, Co 14.0 to 15.5, Al 0.05 to 0.15, with the remainder being Fe and contaminants resulting from the manufacturing process, respectively.

Abstract: A method whereby a composite clad metal ingot can be produced for onward processing at higher temperatures which are sufficient to allow the properties of the substrate material to be adequately controlled to meet specific requirements. These higher temperatures are required to avoid the undue levels of work hardening which occurs at the lower temperatures previously employed because of the need to avoid the formation of deleterious intermetallics at the bonded clad substrate interface. Such intermetallics are formed at temperatures above approximately 850° C. and should they be present, will weaken or destroy the bond.

Abstract: A method whereby a composite clad metal ingot can be produced for onward processing at higher temperatures which are sufficient to allow the properties of the substrate material to be adequately controlled to meet specified requirements. These higher temperatures are required to avoid the undue levels of work hardening which occurs at the lower temperatures previously employed because of the need to avoid the formation of deleterious intermetallics at the bonded clad substrate interface. Such intermetallics are formed at temperatures above approximately 900° C. and should they be present, will weaken or destroy the bond.

Abstract: A method and apparatus for permanently joining two or more metallic vehicle frame components using magnetic impulse welding techniques. The vehicle frame may include a pair of similar or dissimilar tubular side rail members in multiple sections joined together by a plurality of transversely extending tubular or “C” of “U” shaped cross members. A plurality of similar or dissimilar material brackets are joined to the side rails and/or cross members to facilitate the attachment of other portions of the vehicle to the vehicle frame. These components are joined via an overlap joint between two individual side rail sections, a cross member section and a side rail section, or a bracket and a side rail section or a cross member section. The first component and the second component, if tubular side rails, are sized so that they may be disposed telescopically with clearance.

Abstract: There is provided a method of forming a high strength atomic bond between a sputter target and backing plate such that the microstructural characteristics of the sputter target material obtained by prior processing is not altered by the bonding process. There is further provided a method for bonding the target to the backing plate and forming a bonded target/backing plate assembly having a greater target thickness for increased sputtering life, while maintaining the overall standard dimensions set by industry standards.

Abstract: A composite griddle plate is provided having a heavy copper core which is diffusion bonded to one or more outer plates of stainless steel, carbon steel or titanium. The copper cored composite is made by explosion bonding the outer metal plates to the copper core to achieve diffusion bonding followed by multi-pass, small, incremental reduction passes in a hot rolling mill conducted within a narrowly controlled temperature range falling within the overlapping hot working range of the copper core and the dissimilar metal of the outer layers.

Abstract: A method and apparatus for permanently joining two or more metallic vehicle frame components using magnetic impulse welding techniques is disclosed. In a first embodiment, an overlap joint is formed by the joinder of two individual open channel side rail sections to form a portion of a vehicle frame side rail. The first side rail section is initially formed slightly smaller in size than the second side rail section so that it may be disposed telescopically therein with clearance. An electromagnetic coil is provided for generating a magnetic field which causes the side rail sections to move toward one another at a high velocity. The high velocity impact and the large pressures cause the two side rail sections to weld or molecularly bond. Alternatively, a bracket can be joined to a side rail section in a similar manner. In a second embodiment, a pair of closed channel structural members are formed using hydroforming techniques.

Abstract: A method of producing an hermetically sealed bond between a first metal and a second metal wherein the first metal comprises a first portion and a second portion, the method comprising (a) positioning the second portion and the second metal in generally spaced apart parallel relation; and (b) propelling the first portion into collision with the second metal so as to produce the hermetically sealed bond between the first portion and the second metal. The propulsion is preferably effected by a high velocity explosive charge of 5,500-9,000 m/s. The improved resultant bond is hermetically sealed. The process is of value in providing an hermetically sealed chamber, cavity or envelope having improved sealed properties.