Abstract: A vehicle exhaust system is provided that includes a first exhaust member having an end that includes an enlarged section. A second exhaust member is sized to receive a portion of the first exhaust member. The enlarged section of the first exhaust member has an outer diameter that is larger than an inner diameter of at least one section of the second exhaust member for creating an interference condition between the first and second exhaust member to prevent axial movement of the first exhaust member in at least one axial direction. The first exhaust member is secured to the second exhaust member by magnetic pulse welding.

Abstract: A method of manufacturing an exhaust gas manifold, that includes metal exhaust pipes and metal flanges for attaching the pipe openings to corresponding internal combustion engine exhaust ports, employs a hybrid MIG welding process to reduce the occurrences of weld spatter being deposited on the pipe surfaces. Additional benefits are a reduction in applied energy, a resultant reduction in heat being applied to the work pieces, less consumption of weld wire, and improved efficiency of making the weld on the inside surface of the flange adjacent to the pipe opening. The hybrid MIG technique involves moving the head of the weld gun so that its weld wire tip is in contact with the closed path joint formed between an aperture in the flange and the pipe opening. Electrical energy is then applied between the weld wire and the work pieces (flange and pipe) for a relatively short period of time that is sufficient to cause the tip of the weld wire to become a molten drop.

Abstract: A method of manufacturing a torque arm assembly for use in an automotive vehicle utilizing a cold hybrid MIG technique to minimize the introduction of excessive heat into the welded sheet metal panel components of the assembly. Outer and inner metal panels of the assembly are formed with edges along their lengths and are mated with their overlapping edges forming a joint that is welded. The cold hybrid MIG technique involves moving the weld gun so that its weld wire tip is in contact with the outer surface of the inner panel. Applying electrical energy between the weld wire and the panel for a period of time that is sufficient to cause the tip of the weld wire to become a molten drop. Terminating the application of electrical energy and moving the weld wire away from contact to allow the molten wire drop to enter the joint and form the weld. Repeating the weld steps at a high frequency at each point along the joint to is complete the weld along its length.

Abstract: A vehicle exhaust system is provided that includes a first exhaust member having an end that includes an enlarged section. A second exhaust member is sized to receive a portion of the first exhaust member. The enlarged section of the first exhaust member has an outer diameter that is larger than an inner diameter of at least one section of the second exhaust member for creating an interference condition between the first and second exhaust member to prevent axial movement of the first exhaust member in at least one axial direction. The first exhaust member is secured to the second exhaust member by magnetic pulse welding.