Abstract: A fastener assembly for use with one or more workpieces. The fastener assembly can be a single-sided (i.e., blind) fastener assembly in which the fastener assembly is inaccessible from one side of the workpiece(s). In this regard, the workpiece(s) can make-up an enclosed component, for example. The fastener assembly can have a fastening end, such as a threaded stud, for securement with a distinct component that is otherwise detached from the fastener assembly. The workpiece(s) can be composed of a carbon fiber composite material, an aluminum material, or another type of material.

Abstract: A clamp system and method for measurement and control of welding a first substrate to a second substrate is provided. The system comprises a squeeze clamp having to a first end and a second end. The system further comprises a motor connected to the squeeze clamp such that the first and second ends are movable to clamp the first substrate to the second substrate. The system further comprises at least one of an electromagnetic flux sensor, a current sensor, a position sensor, and a gap sensor disposed on one of the first and second ends for determining a first measured variable between the first and second substrates. The system further comprises a controller to control the motor to clamp the first substrate to the second substrate based on the first measured variable. The controller is in communication with the electromagnetic flux sensor, the current sensor, and the gap sensor.

Abstract: A method of joining includes disposing a second workpiece adjacent to a first workpiece. The method further includes identifying a determined hardness parameter of at least one of the first and second workpieces at a welding position. The determined hardness parameter is determined by at least one of estimation, calculation, and measurement. The method includes selecting a weld schedule based on the determined hardness parameter and welding the first and second workpieces together using the selected weld schedule. A welding horn includes a shank and a tip having an end face, the tip being disposed at an end of the shank and configured to contact a workpiece and to transmit energy to the workpiece. Knurls are disposed on the end face, each knurl having a distal end. A curved indenter extends from the end face beyond the distal ends of the knurls.

Abstract: A rivet nut (“rivnut”) installation method and a rivnut structural configuration are disclosed that can be implemented separately in conjunction with one another to serve as an anchor in and/or a workpiece at an installation location. The rivnut installation method involves inserting a rivnut onto an externally threaded mandrel, rotating the mandrel while a free end of the mandrel is in contact with the workpiece, and driving the free end of the mandrel and the rivnut through the workpiece while continuing to rotate the mandrel. The method is particularly useful when the workpiece includes one or more substrate layers composed of a low ductility material such as a polymer composite. The rivnut structural configuration includes the incorporation of an external threading onto at least a portion of a hollow shaft of the rivnut.

Abstract: A fastening assembly includes a panel defining an aperture, a fastener having a head, a shaft portion extending from the head, and a recess formed in the head, and a sacrificial primary anode insert disposed in the recess. The sacrificial primary anode insert is configured to corrode at a rate faster than a corrosion rate of the fastener.

Abstract: A clamp system and method for measurement and control of welding a first substrate to a second substrate is provided. The system comprises a squeeze clamp having to a first end and a second end. The system further comprises a motor connected to the squeeze clamp such that the first and second ends are movable to clamp the first substrate to the second substrate. The system further comprises at least one of an electromagnetic flux sensor, a current sensor, a position sensor, and a gap sensor disposed on one of the first and second ends for determining a first measured variable between the first and second substrates. The system further comprises a controller to control the motor to clamp the first substrate to the second substrate based on the first measured variable. The controller is in communication with the electromagnetic flux sensor, the current sensor, and the gap sensor.

Abstract: A system and method of enhanced automated welding of a first workpiece and a second workpiece are provided. The method comprises providing a system for intelligent robot-based welding of the first workpiece and the second workpiece. The method further comprises determining a geometrical location of the first workpiece and the second workpiece to be welded at a welding sequence based a predetermined process variable. The method further comprises adjusting the predetermined process variable based on the geometrical location of the first and second workpieces to define an actual process variable. The method further comprises welding a first portion of the first and second workpieces with the actual process variable to define a first welded portion. The method further comprises determining a weld quality of the first welded portion.

Abstract: A fastening assembly includes a panel, a fastener and a primary anode insert. The panel defines an aperture and the fastener includes a shaft portion disposed within the aperture. The primary anode insert may be disposed adjacent to a reaction region of the fastener. Alternatively, the fastening assembly may include a fastener and a primary anode insert. The fastener includes a shaft portion which is configured to be disposed within at least two aligned component apertures. The primary anode insert may be also be disposed adjacent to a reaction region of the fastener.

Abstract: A weld system includes: a robot control module configured to actuate a robot and move a welder along a joint of metal workpieces during welding, the welder being attached to the robot; a weld control module configured to, during the welding, apply power to the welder, supply a shield gas, and supply electrode material; a vision sensor configured to, during the welding, optically measure distances between the vision sensor and locations, respectively, on an outer surface of a weld bead created along the joint by the welder; and a weld module configured to: determine a strength of the weld bead at a location based on: the distances at the location along the joint; and at least one parameter from at least one of the robot control module during the welding, the weld control module during the welding, and a sensor configured to capture data of the welding during the welding.

Abstract: A method of joining includes disposing a second workpiece adjacent to a first workpiece. The method further includes identifying a determined hardness parameter of at least one of the first and second workpieces at a welding position. The determined hardness parameter is determined by at least one of estimation, calculation, and measurement. The method includes selecting a weld schedule based on the determined hardness parameter and welding the first and second workpieces together using the selected weld schedule. A welding horn includes a shank and a tip having an end face, the tip being disposed at an end of the shank and configured to contact a workpiece and to transmit energy to the workpiece. Knurls are disposed on the end face, each knurl having a distal end. A curved indenter extends from the end face beyond the distal ends of the knurls.

Abstract: Apparatus are provided for ultrasonic welding of a workpiece of one or more components. The apparatus includes a horn configured to contact the workpiece and to transmit energy to the workpiece. The horn includes a shank and a tip disposed at an end of the shank facing the workpiece. The tip has a face that has a tip radius forming a curved surface at the face. A knurl is formed on the face across the curved surface.

Abstract: A method of forming an assembly includes providing a metallic first workpiece having base and a first layer disposed on the base and adhering a second layer onto the first layer. One of the first and second layers is formed of a zinc-based material formed of at least a majority of zinc, and the other of the first and second layers is formed of a metallic alloying material having a melting point higher than the melting point of the zinc-based material. Preferably, the first layer is formed of the zinc-based material, and the second layer is formed of the metallic alloying material with the higher melting point. A metallic second workpiece is disposed in contact with the second layer. A welding operation is performed to join the first workpiece to the second workpiece. A welded assembly is also provided.

Abstract: Apparatus are provided for ultrasonic welding of a workpiece of one or more components. The apparatus includes a horn configured to contact the workpiece and to transmit energy to the workpiece. The horn includes a shank and a tip disposed at an end of the shank facing the workpiece. The tip has a face that has a tip radius forming a curved surface at the face. A knurl is formed on the face across the curved surface.

Abstract: A method of joining a multiple member work-piece includes providing a first steel work-piece having a first thickness and a second steel work-piece having a second thickness. The first thickness is at least twice the second thickness. A third material is disposed in contact with the second steel work-piece. For example, the third material may be in the form of a rivet, a plurality of pins, or a coating material. The method includes resistance welding the first and second work-pieces together. A bonded assembly includes the first and second steel members and the third material being bonded together, where the thickness of the first member is at least twice the thickness of the second member.

Abstract: A method of joining a multiple member work-piece includes providing a first steel work-piece having a first electrical resistivity and a second steel work-piece having a second electrical resistivity that is lower than the first electrical resistivity. A third material is disposed in contact with the second steel work-piece. The third material has an electrical resistivity that is greater than the second electrical resistivity. The method includes resistance welding the first and second work-pieces together. The third material may be in the form of a rivet, a third work-piece, or a coating material disposed between the first and second work-pieces. A bonded assembly includes steel members and a third material being bonded together, wherein the electrical resistivity of the second member is lower than the electrical resistivity of the first member, and the third material has an electrical resistivity that is greater than the electrical resistivity of the second member.

Abstract: A method of resistance welding includes providing a first steel workpiece and second steel workpiece each having a zinc (Zn) coating. A first portion of the first steel workpiece and a second portion of the second steel workpiece are heated to at least about 500° C. allowing the zinc (Zn) coating to melt and dissolution of iron Fe from the first and second steel workpieces into the melted zinc (Zn) coating to form at least one of a plurality of Iron-Zinc intermetallic compounds. The first portion of the first workpiece and the second portion of the second workpiece are cooled to a first temperature. The first workpiece is disposed in contact with the second workpiece such that the first portion of the first workpiece is aligned with the second portion of the second workpiece. The first portion of the first workpiece is welded to the second portion of the second workpiece.

Abstract: A double ended dual attached fastener includes a first portion having a stud bolt, a second portion configured to anchor to a panel member, and a flange nut partitioning the first end and the second end. The flange nut includes a flat interior annular surface facing the second portion. The flange nut includes a plurality of radially spaced weld projections extending toward the second portion. The weld projection includes a material that amendable to form a weld joining the flange nut to a panel member through which the second portion is inserted. The second portion defines a fastener selected from a group consisting of a self-tapping friction screw, a self-piercing rivet, and a swage bolt.

Abstract: A weld rivet for use in a method of resistance element welding of dissimilar materials includes a shank portion, a cap portion, and a coating. The shank portion has a cylindrical shape, a first end, and a second end opposite the first end. The cap portion has a flat disc shape, a top surface, and a bottom surface. The bottom surface of the cap portion is disposed on the first end of the shank portion. The coating is disposed on the bottom surface of the cap portion. The coating electrically insulates the cap portion.

Abstract: A method of joining first and second layers of polymeric composite material includes disposing a portion of a molded insert having a bottom end into a top surface of a first layer of material and then applying a layer of adhesive between the top surface of the first layer and a bottom surface of a second layer of material to create a bond-line thickness. Next, a top surface of the second layer is pierced with a headless end of a fastener and interlocked into the molded insert. A layer of protective coating is then applied to the top surface of the second layer of material to cover the interlocked fastener.

Abstract: Methods for ultrasonic welding of thermoplastic polymer workpieces and assemblies made therefrom are provided. The method may comprise disposing a first region of a first thermoplastic polymer workpiece and a second region of a second thermoplastic polymer workpiece between an ultrasonic horn and an anvil of an ultrasonic welding device. The first workpiece has a preformed deformation and at least one of the first and/or second workpieces has an adhesive precursor applied thereto. The ultrasonic horn or anvil seats within the preformed deformation. Ultrasonic energy is applied from the ultrasonic horn to create a weld nugget between the first and second workpieces. The assembly thus formed has a green strength sufficient to be further processed immediately. The methods provide a robust weld joint with controlled adhesive bondline thickness.