Method for attaching metallic members

Claim 1

As a substitute for welding, the method of securing together a first and second metallic body along first and second respective adjacent surface portions comprising the steps of forming a first reentrantly shaped opening extending from said first surface portion into said first body, forming a second reentrantly shaped opening extending from said second surface portion into said second body, placing said first and second surface portions of said first and second bodies in contact with one another, aligning said first and second openings with respect to one another, roughening the interior surfaces of said first and second reentrantly shaped openings to a finishing number in the range of 125-1,000 to provide an adhesive force joining a slug subsequently formed therein to said interior surfaces, pouring a molten castable insert material having a melting point above 1,000* F. into the full volume of the cavity formed by said first and second openings to define said slug, and cooling said molten material to solidify said slug which completely fills the volume of said cavity, the mass of said slug being small relative to the masses of said first and second bodies so that the temperature rise of said first and second metallic bodies is relatively small when said castable insert material is poured into said first and second openings.