Friction welding of X-ray tube components using intermediate filler materials

An assembly adapted for use with an x-ray tube, the assembly comprising:

• a. a first component formed of a first material and having a first mating surface thereon;
• b. a second component formed of a second material and having a second mating surface thereon, the second mating surface defining a space with the first mating surface;
• and
• c. an intermediate member disposed within the space between the first mating surface and the second mating surface, wherein the intermediate member is selected from the group consisting of copper, copper-germanium alloy, copper-silicon alloy, copper-gold alloy, and copper-palladium alloy.

An assembly adapted for use with an x-ray tube, the assembly comprising:

• a. a first component formed of a first material and having a first mating surface thereon;
• b. a second component formed of a second material and having a second mating surface thereon, the second mating surface defining a space with the first mating surface;
• and
• c. an intermediate member disposed within the space between the first mating surface and the second mating surface, wherein at least one of the first mating surface and the second mating surface includes a mechanical interlocking feature.

A method for forming an assembly for use in an x-ray tube, the method comprising the steps of:

• a) providing a first component formed of a first material and having a first mating surface thereon, a second component formed of a second material and having a second mating surface thereon that defines a space with the first mating surface, wherein the space is substantially enclosed by the first mating surface and the second mating surface;
• b) placing an intermediate filler material between the first mating surface and the second mating surface;
• and
• c) pressing the first component and the second component towards one another to form a joint between the first mating surface and the second mating surface within the space of the intermediate filler material.

A method for forming an assembly for use in an x-ray tube, the method comprising the steps of:

• a) providing a first component formed of a first material and having a first mating surface thereon, a second component formed of a second material and having a second mating surface thereon that defines a space with the first mating surface;
• b) placing an intermediate filler material between the first mating surface and the second mating surface;
• and
• c) pressing the first component and the second component towards one another to form a joint between the first mating surface and the second mating surface within the space of the intermediate filler material, wherein the step of pressing the first component and the second component towards one another comprises friction welding the first component and the second component to one another and wherein the step of friction welding the first component and second component to one another is performed at atmospheric temperature and pressure.

A method for forming an assembly for use in an x-ray tube, the method comprising the steps of:

• d) providing a first component formed of a first material and having a first mating surface thereon, a second component formed of a second material and having a second mating surface thereon that defines a space with the first mating surface;
• e) placing an intermediate filler material between the first mating surface and the second mating surface;
• and
• f) pressing the first component and the second component towards one another to form a joint between the first mating surface and the second mating surface within the space of the intermediate filler material, wherein the step of providing the first component and the second component comprises forming at least one mechanical interlocking feature on at least one of the first mating surface or the second mating surface.

An x-ray tube comprising:

• a) a frame defining an enclosure;
• b) a cathode assembly disposed in the enclosure;
• and
• c) an anode assembly disposed in the enclosure spaced from the cathode assembly, wherein the anode assembly comprises:
• i. a first component formed of a first material and having a first mating surface thereon;
• ii. a second component formed of a second material and having a second mating surface thereon, the second mating surface defining a space with the first mating surface, the space at least substantially enclosed between the first mating surface and the second mating surface;
• and
• iii. an intermediate filler member disposed within the space between the first mating surface and the second mating surface to form a joint therebetween.