Abstract: Disclosed herein are joining methods (e.g., methods of forming a joined material) and devices comprising materials joined by said methods. For example, the disclosed subject matter related to methods of joining one or more metallized polymer current collectors together and/or to a tab. For example, the methods can comprise: placing one or more metallized polymer current collector proximate a tab, such that at least a portion of the metallized polymer current collector(s) overlaps with at least a portion of the tab in an overlap region; placing a conductive material proximate the overlap region; inducing flow of the conductive material such that the conductive material flows at least between the portion of the metallized polymer current collector(s) and the portion of the tab; and subsequently solidifying the conductive material, thereby forming a joint that joins the metallized polymer current collector(s) to the tab.

Abstract: An ultrasonic resistance welding apparatus 10 contains a resistance spot welding apparatus 15, a first electrode 16 and a vibrable second electrode 18, the vibrable second electrode 18 in operable communication with an ultrasonic transducer 12, whereby the ultrasonic transducer 12 selectively imparts vibratory energy to the vibrable second electrode 18 based on signals from a controller 32. The vibrable second electrode 18 may be tuned or designed to resonate within 2.5% of an operating frequency of the ultrasonic transducer 12. During operation of the welding apparatus 10, a tip 19 of the second vibrable electrode 18 may be positioned at an anti-nodal point 38 of the vibratory energy and the vibrable second electrode 18 may be attached to the resistance spot welding apparatus 15 at a nodal plane 36 of the vibratory energy. A process for employing the apparatus 10 is also presented.

Abstract: A method for ultrasonic debulking a composite laminate includes the steps of defining a path across the laminate, the path having a starting location and an ending location and applying a force to and transmitting ultrasonic vibration into the laminate along the path, beginning at the starting location and ending at the ending location. The method further includes determining a temperature of a surface of the laminate proximate to the path and varying at least one of an amplitude of the ultrasonic vibration, the applied force, a feed rate at which the force and the ultrasonic vibration are applied along the path, an angle at which the ultrasonic vibration is applied to the laminate, and an interval at which plies of the laminate are processed, based upon the determined temperature of the surface of the laminate.

Abstract: A method for ultrasonic debulking a composite laminate includes the steps of defining a path across the laminate, the path having a starting location and an ending location and applying a force to and transmitting ultrasonic vibration into the laminate along the path, beginning at the starting location and ending at the ending location. The method further includes determining a temperature of a surface of the laminate proximate to the path and varying at least one of an amplitude of the ultrasonic vibration, the applied force, a feed rate at which the force and the ultrasonic vibration are applied along the path, an angle at which the ultrasonic vibration is applied to the laminate, and an interval at which plies of the laminate are processed, based upon the determined temperature of the surface of the laminate.

Abstract: A method for ultrasonic debulking a composite laminate (105) includes the steps of defining a path (115) across the laminate, the path having a starting location and an ending location and applying a force (109) to and transmitting ultrasonic vibration (111) into the laminate along the path, beginning at the starting location and ending at the ending location. The method further includes determining a temperature of a surface (103, 123) of the laminate proximate to the path and varying at least one of an amplitude of the ultrasonic vibration, the applied force, a feed rate at which the force and the ultrasonic vibration are applied along the path, an angle at which the ultrasonic vibration is applied to the laminate, and an interval at which plies of the laminate are processed, based upon the determined temperature of the surface of the laminate.

Abstract: A method for ultrasonic debulking a composite laminate (105) includes the steps of defining a path (115) across the laminate, the path having a starting location and an ending location and applying a force (109) to and transmitting ultrasonic vibration (111) into the laminate along the path, beginning at the starting location and ending at the ending location. The method further includes determining a temperature of a surface (103, 123) of the laminate proximate to the path and varying at least one of an amplitude of the ultrasonic vibration, the applied force, a feed rate at which the force and the ultrasonic vibration are applied along the path, an angle at which the ultrasonic vibration is applied to the laminate, and an interval at which plies of the laminate are processed, based upon the determined temperature of the surface of the laminate.