Abstract: A method for welding/brazing a tube to a member. The tube has an axially-extending first portion and has a tube form which extends transversely from the first portion. A filler material is obtained. The tube, the member and the filler material are positioned such that the filler material contacts the tube form and the member. A resistance current path is created through the tube, the filler material and the member which melts at least some of the filler material creating a weld/braze zone which includes at least some of the tube, at least some of the member, and at least some of the filler material.

Abstract: Welded structures having a first and a second member formed from sheet metal, tubes, and similar shapes, are economically fabricated through use of a method for joining a second member to a first member having a folded rim extending therefrom. The folded rim defines an air gap within the folded rim. The first and second members are joined together by forcing the folded rim against the second member under sufficient pressure to flatten the folded rim to a point that there remains substantially no air gap inside the folded rim, and resistance welding together the first and second members. The second member and the rim respectively define faying surfaces thereof. The air gap inside the folded rim extends generally parallel to the faying surfaces. The faying surfaces of the rim and second member are forced against one another by applying pressure through the folded rim in a direction generally perpendicular to the faying surfaces.

Abstract: A method for metallurgically joining a tube to a member. A tube having a flange is obtained, and a member is obtained. A welding/brazing electrode wheel is obtained having an axis of rotation and having a rim. The tube and the member are positioned with the flange contacting the member directly and/or indirectly through an intervening welding/brazing joining material. The rim of the electrode wheel is positioned in direct contact with the flange. A resistance welding/brazing current path is created through the flange and the member using at least the electrode wheel creating a seam weld/braze zone which includes at least some of the flange and at least some of the member. During the current path creation step, the electrode wheel is rotated about the axis of rotation.

Abstract: A method for joining a tube to a member. A tube having a flange is obtained, and a member is obtained. The tube and the member are positioned with the flange contacting the member either directly or indirectly through an intervening joining material. The tube and/or the member are locally heated proximate the contact of the flange and the member without substantially heating the tube and/or the member apart from proximate the contact of the flange and the member. In one example, the local heating is welding, with or without a filler material, such as resistance welding, laser-beam welding or electron-beam welding. In another example, the local heating is brazing. In an additional example, a curable adhesive joining material is placed on the flange and/or the member, wherein the adhesive is located between and directly contacts the flange and the member, and wherein the local heating cures the adhesive.

Abstract: A method for metallurgically joining a tube to a member. A tube having a flange is obtained, and a member is obtained. The tube and the member are positioned with the flange contacting the member directly and/or indirectly through an intervening welding/brazing joining material. The flange and/or the member is segmented and their contact is a segmented contact at spaced-apart contact areas between the flange and the member. A resistance welding/brazing current path is created,through the tube and the member at a first contact area creating a first weld/braze zone which includes at least some of the flange and at least some of the member. Then, a resistance welding/brazing current path is created through the tube and the member at a different second contact area creating a second weld/braze zone which includes at least some of the flange and at least some of the member.

Abstract: A method for resistance welding/brazing a tube to a container. A tube is obtained having an axially-extending first portion and a tube form which extends transversely from the first portion. A container is obtained having an orifice. A support tool is obtained with an expandable head. The tube form is positioned proximate the outer surface of the container and surrounding the orifice. The unexpanded head of the support tool is passed through the orifice of the container. The head of the support tool is expanded inside the container. The inner surface of the container is supported with the expanded head of the support tool. A resistance current path is created through the tube form and the container creating a weld/braze zone which includes at least some of the tube form and at least some of the container.

Abstract: A method for metallurgically joining a tube to a member. A tube is obtained having a longitudinal axis and having an end portion, wherein the end portion includes a fold, and wherein the fold includes longitudinally-spaced-apart first and second fold portions. A member (such as, but not limited to, a plate or a second tube) is obtained. The tube and the member are disposed with the end portion contacting the member. A resistance welding current path is created through the tube and the member proximate the end portion and the end portion is relatively longitudinally moved deformingly against the member creating a weld zone which includes at least some of the end portion and at least some of the member.

Abstract: A method and apparatus for testing specimens by means of ultrasonic waves. A fixture adapted to hold a test specimen is placed in a fluid reservoir. At least one test probe adapted to emit and receive ultrasonic waves is positioned in proximity to the test specimen, which is mounted to the test fixture. The test probe and/or the test specimen may be adapted to rotate and translate in relation to each other in a predetermined fashion during testing, subjecting a greater portion of the test specimen to the ultrasonic test signals for more complete coverage of the test specimen.

Abstract: A method for resistance welding/brazing a tube to a container. A tube is obtained having an axially-extending first portion and a tube form which extends transversely from the first portion. A container is obtained having an orifice. A support tool is obtained with an expandable head. The tube form is positioned proximate the outer surface of the container and surrounding the orifice. The unexpanded head of the support tool is passed through the orifice of the container. The head of the support tool is expanded inside the container. The inner surface of the container is supported with the expanded head of the support tool. A resistance current path is created through the tube form and the container creating a weld/braze zone which includes at least some of the tube form and at least some of the container.

Abstract: A method for welding/brazing a tube to a member. The tube has an axially-extending first portion and has a tube form which extends transversely from the first portion. A filler material is obtained. The tube, the member and the filler material are positioned such that the filler material contacts the tube form and the member. A resistance current path is created through the tube, the filler material and the member which melts at least some of the filler material creating a weld/braze zone which includes at least some of the tube, at least some of the member, and at least some of the filler material.

Abstract: A method for resistance welding a tube to a member. A tube is obtained having an axially-extending first portion and having a tube form which extends transversely from the first portion. The tube form has at least one axial projection. The tube and the member are positioned with the at-least-one axial projection in contact with the member. A resistance welding current path is created through the member and the tube including the at-least-one axial projection creating a weld zone which includes at least some of the at-least-one axial projection and at least some of the member.

Abstract: A method for metallurgically attaching a tube to a member. A member having a wall is obtained. The wall includes opposing first and second sides and includes a partial extrusion extending above the first side. The partial extrusion has a through hole. A tube having an end portion is obtained. The tube and the member are positioned with the end portion contacting the second side of the wall proximate the partial extrusion. A resistance welding current path is created through the tube and the member proximate the end portion and the partial extrusion, and the end portion is relatively moved into and deformingly against the partial extrusion creating a weld zone which includes at least some of the end portion and at least some of the partial extrusion.

Abstract: A method for resistance welding a tube to a member. A tube is obtained having an axially-extending first portion and having a tube form which extends transversely from the first portion. The tube form has at least one axial projection. The tube and the member are positioned with the at-least-one axial projection in contact with the member. A resistance welding current path is created through the member and the tube including the at-least-one axial projection creating a weld zone which includes at least some of the at-least-one axial projection and at least some of the member.

Abstract: A method for metallurgically attaching together two tubes. A first tube is obtained having a far wall portion with a first through hole and a near wall portion with a second through hole. A second tube is obtained including first and second outward folds. The tubes are positioned with the first fold passed through the second through hole and contacting the far wall portion surrounding the first through hole and with the second fold located outside the near wall portion. A first resistance welding current path is created proximate the first fold and the far wall portion and the first fold is relatively moved deformingly against the far wall portion creating a first weld zone. A second resistance welding current path is created proximate the second fold and the near wall portion and the second fold is relatively moved deformingly against the near wall portion creating a second weld zone.

Abstract: Welded structures having a first and a second member formed from sheet metal, tubes, and similar shapes, are economically fabricated through use of a method for joining a second member to a first member having a folded rim extending therefrom. The folded rim defines an air gap within the folded rim. The first and second members are joined together by forcing the folded rim against the second member under sufficient pressure to flatten the folded rim to a point that there remains substantially no air gap inside the folded rim, and resistance welding together the first and second members. The second member and the rim respectively define faying surfaces thereof. The air gap inside the folded rim extends generally parallel to the faying surfaces. The faying surfaces of the rim and second member are forced against one another by applying pressure through the folded rim in a direction generally perpendicular to the faying surfaces.

Abstract: A method for metallurgically attaching together two tubes. A first tube is obtained having a far wall portion with a first through hole and a near wall portion with a second through hole. A second tube is obtained including first and second outward folds. The tubes are positioned with the first fold passed through the second through hole and contacting the far wall portion surrounding the first through hole and with the second fold located outside the near wall portion. A first resistance welding current path is created proximate the first fold and the far wall portion and the first fold is relatively moved deformingly against the far wall portion creating a first weld zone. A second resistance welding current path is created proximate the second fold and the near wall portion and the second fold is relatively moved deformingly against the near wall portion creating a second weld zone.

Abstract: A method for manufacturing a tubular assembly. A first tube is obtained. A first tubular connector is obtained having a first and second end portions. The first end portion is metallurgically attached to the first tube. A tubular member is obtained having a third end portion. At least one of the second and third end portions includes an annular outward fold including spaced-apart first and second fold portions. The first tubular connector and the tubular member are positioned with the second end portion aligned with and contacting the third end portion. A resistance welding current path is created through the first tubular connector and the tubular member proximate the second and third end portions and the second and third end portions are relatively and deformingly moved together creating a weld zone which includes at least some of the second and third end portions.

Abstract: A method for metallurgically joining a tube to a member. A tube having a flange is obtained, and a member is obtained. A welding/brazing electrode wheel is obtained having an axis of rotation and having a rim. The tube and the member are positioned with the flange contacting the member directly and/or indirectly through an intervening welding/brazing joining material. The rim of the electrode wheel is positioned in direct contact with the flange. A resistance welding/brazing current path is created through the flange and the member using at least the electrode wheel creating a seam weld/braze zone which includes at least some of the flange and at least some of the member. During the current path creation step, the electrode wheel is rotated about the axis of rotation.

Abstract: A method for metallurgically joining a tube to a member. A tube having a flange is obtained, and a member is obtained. The tube and the member are positioned with the flange contacting the member directly and/or indirectly through an intervening welding/brazing joining material. The flange and/or the member is segmented and their contact is a segmented contact at spaced-apart contact areas between the flange and the member. A resistance welding/brazing current path is created,through the tube and the member at a first contact area creating a first weld/braze zone which includes at least some of the flange and at least some of the member. Then, a resistance welding/brazing current path is created through the tube and the member at a different second contact area creating a second weld/braze zone which includes at least some of the flange and at least some of the member.

Abstract: A method for metallurgically attaching a tube to a member. A member having a wall is obtained. The wall includes opposing first and second sides and includes a partial extrusion extending above the first side. The partial extrusion has a through hole. A tube having an end portion is obtained. The tube and the member are positioned with the end portion contacting the second side of the wall proximate the partial extrusion. A resistance welding current path is created through the tube and the member proximate the end portion and the partial extrusion, and the end portion is relatively moved into and deformingly against the partial extrusion creating a weld zone which includes at least some of the end portion at least some of the partial extrusion.