Abstract: Methods of fastening are provided. A method comprises contacting a fastener with a first layer of an assembly at a first location. The assembly comprises the first layer, a third layer, and a second layer positioned intermediate the first layer and the third layer. The first layer, the third layer, and the fastener are electrically conductive. The second layer defines a gap and the first location is in communication with the gap. Electrical communication is formed between the assembly and the fastener. The first layer is fastened to the third layer through the gap in the second layer with the fastener. The fastening comprises resistance welding the fastener to the third layer.

Abstract: A collet assembly including an actuator and a collet connected to the actuator. The collet assembly is adapted to be installed on a welding electrode holder having an electrode. The collet is moveable by the actuator from an advanced position, in which the collet is adapted to grip a fastener such as a welding rivet, and a retracted position, in which at least a portion of the collet is retracted into the actuator to enable the electrode to engage the fastener for welding to a work piece, and the collet is adapted to release the fastener.

Abstract: Methods of fastening are provided. A method comprises contacting a fastener with a first layer of an assembly at a first location. The assembly comprises the first layer, a third layer, and a second layer positioned intermediate the first layer and the third layer. The first layer, the third layer, and the fastener are electrically conductive. The second layer defines a gap and the first location is in communication with the gap. Electrical communication is formed between the assembly and the fastener. The first layer is fastened to the third layer through the gap in the second layer with the fastener. The fastening comprises resistance welding the fastener to the third layer.

Abstract: Rivet dispenser systems and methods of use thereof are provided. In a non-limiting embodiment, the rivet dispenser system comprises a rivet receiving member defining a channel therein, and a seat member. The channel includes a curved region. The rivet receiving member comprises a first port and a second port. The first port communicates with the channel and is configured to receive rivets. The second port communicates with the channel and is configured to dispense rivets. The channel extends between the first port and the second port and is configured to transport rivets from the first port to the second port in a series arrangement and in a preselected orientation. The seat member communicates with the second port and is configured to selectively engage with a rivet holder of a resistance spot rivet welding apparatus and introduce a single rivet to the rivet holder at one time.

Abstract: Resistance spot rivet welding systems, subsystems, and methods of use thereof are provided.

Abstract: Rivet dispenser reloading systems and methods of use thereof are provided. A non-limiting embodiment of a rivet dispenser reloading system comprises a receiving member defining a channel therein, and a first gate. The rivet receiving member comprises a first port and a second port that communicate with the channel. The first port is configured to receive rivets. The second port is configured to selectively engage with a rivet dispenser and introduce rivets to the rivet dispenser. The channel extends between the first port and the second port and is configured to transport rivets from the first port to the second port in a series arrangement and in a preselected orientation. The first gate is in communication with the second port and is selectively positionable between a first configuration inhibiting movement of rivets through the second port, and a second configuration enabling movement of rivets through the second port.

Abstract: Rivet dispenser systems and methods of use thereof are provided. In a non-limiting embodiment, the rivet dispenser system comprises a rivet receiving member defining a channel therein, and a seat member. The channel includes a curved region. The rivet receiving member comprises a first port and a second port. The first port communicates with the channel and is configured to receive rivets. The second port communicates with the channel and is configured to dispense rivets. The channel extends between the first port and the second port and is configured to transport rivets from the first port to the second port in a series arrangement and in a preselected orientation. The seat member communicates with the second port and is configured to selectively engage with a rivet holder of a resistance spot rivet welding apparatus and introduce a single rivet to the rivet holder at one time.

Abstract: A hybrid electrode for resistance spot welding and a method of resistance welding are provided. The hybrid electrode comprises a pin and a collar member. The pin comprises an electrically conductive material and a pin contact surface. The collar member comprises a material that is at least one of less electrically conductive than the electrically conductive material of the pin and less thermally conductive than the electrically conductive material of the pin. The collar member comprises a collar member contact surface, and defines an inner cavity and a longitudinal axis. The pin is at least partially disposed in the inner cavity and the pin contact surface extends away from the collar member and is offset a distance along the longitudinal axis from the collar member contact surface.

Abstract: An apparatus and method for fastening dissimilar materials like steel, plastic and aluminum. A resistance welding fastener having multiple layers may be used with or without a sealant. The fastener may be used to form an aluminum covered steel laminate via a hemming pattern of attachment. The fastener may have a solid shaft or have an extended reach and have features for interacting with the welding electrode. A variety of electrode tips may be employed to cooperate with the fastener.

Abstract: Rivet dispenser systems and methods of use thereof are provided. In a non-limiting embodiment, the rivet dispenser system comprises a rivet receiving member defining a channel therein, and a seat member. The channel includes a curved region. The rivet receiving member comprises a first port and a second port. The first port communicates with the channel and is configured to receive rivets. The second port communicates with the channel and is configured to dispense rivets. The channel extends between the first port and the second port and is configured to transport rivets from the first port to the second port in a series arrangement and in a preselected orientation. The seat member communicates with the second port and is configured to selectively engage with a rivet holder of a resistance spot rivet welding apparatus and introduce a single rivet to the rivet holder at one time.

Abstract: Rivet dispenser reloading systems and methods of use thereof are provided. A non-limiting embodiment of a rivet dispenser reloading system comprises a receiving member defining a channel therein, and a first gate. The rivet receiving member comprises a first port and a second port that communicate with the channel. The first port is configured to receive rivets. The second port is configured to selectively engage with a rivet dispenser and introduce rivets to the rivet dispenser. The channel extends between the first port and the second port and is configured to transport rivets from the first port to the second port in a series arrangement and in a preselected orientation. The first gate is in communication with the second port and is selectively positionable between a first configuration inhibiting movement of rivets through the second port, and a second configuration enabling movement of rivets through the second port.

Abstract: An apparatus and method for fastening dissimilar materials like steel, plastic and aluminum. A resistance welding fastener having multiple layers may be used with or without a sealant. The fastener may be used to form an aluminum covered steel laminate via a hemming pattern of attachment. The fastener may have a solid shaft or have an extended reach and have features for interacting with the welding electrode. A variety of electrode tips may be employed to cooperate with the fastener.

Abstract: A method for resistance spot welding aluminum alloys includes reducing the electrical resistance of an outer surface of the stackup in contact with the anode while leaving the faying surfaces at higher resistances, e.g., by grit blasting the anode contacting surface. High resistance electrodes, e.g., with refractory metal content may be used. Stackups of greater than two members may be used. Sheet material may be prepared having the lower and higher resistance surfaces and used with other sheets having higher resistance surfaces. The cathode contacting surface of the stackup may also have a reduced resistance. The method and sheet may be used in assembling vehicle bodies.

Abstract: An apparatus and method for fastening dissimilar materials like steel, plastic and aluminum. A resistance welding fastener having multiple layers may be used with or without a sealant. The fastener may be used to form an aluminum covered steel laminate via a hemming pattern of attachment. The fastener may have a solid shaft or have an extended reach and have features for interacting with the welding electrode. A variety of electrode tips may be employed to cooperate with the fastener.

Abstract: Resistance spot rivet welding systems, subsystems, and methods of use thereof are provided.

Abstract: A collet assembly including an actuator and a collet connected to the actuator. The collet assembly is adapted to be installed on a welding electrode holder having an electrode. The collet is moveable by the actuator from an advanced position, in which the collet is adapted to grip a fastener such as a welding rivet, and a retracted position, in which at least a portion of the collet is retracted into the actuator to enable the electrode to engage the fastener for welding to a work piece, and the collet is adapted to release the fastener.

Abstract: An apparatus and method for method for joining materials includes a rivet that may extend through a first sheet to be resistance welded to a second sheet. The head of the rivet has a cavity and vents allowing adhesive extruded from a pilot hole to be received in the cavity and vented in a direction parallel to the first sheet. The rivet is deformed to an hourglass shape that fills the pilot hole and displaces the first sheet into the cavity. Rivet dimension allow for holding with a robotic gripper that can be withdrawn before welding. Methods of monitoring joint quality include comparing welding parameter profiles and images of good and discrepant joints.

Abstract: An apparatus and method for fastening layers of non-ferrous alloys, like aluminum, magnesium and copper utilizes a steel fastener and a spot welding machine. The fastener and metals are stacked and the heat from the welder's electric current softens the lower melting point aluminum allowing the fastener to penetrate the aluminum. A weld zone between the fastener and the various layers creates an internal weld. The fastener has a rough shaft that is coated by the molten weld zone and is hard to withdraw on solidification. Layers of non-conductive materials like plastics and ceramics may also be affixed to a conductive layer using a fastener made from a compatible material that extends through a pilot hole and welds to or penetrates a conductive layer. The fastener may have projections that initially reduce contact area with the stack.

Abstract: An apparatus and method for fastening dissimilar metals like steel and aluminum utilizes a steel rivet and a spot welding machine. The rivet and metals are stacked and the heat from the welder's electric current softens the lower melting point aluminum allowing the rivet to penetrate the aluminum and weld to the steel layer. The fastener may be used to join stacks with several layers of different materials and may be used to apply a threaded socket or stud made from steel or titanium to an aluminum or magnesium alloy structure. Layers of non-conductive materials like plastic and ceramics may also be affixed to a conductive layer using the fastener made from a compatible material that extends through a pilot hole.

Abstract: An apparatus and method for fastening dissimilar metals like steel and aluminum utilizes a steel rivet and a spot welding machine. The rivet and metals are stacked and the heat from the welder's electric current softens the lower melting point aluminum allowing the rivet to penetrate the aluminum and weld to the steel layer. The fastener may be used to join stacks with several layers of different materials and may be used to apply a threaded socket or stud made from steel or titanium to an aluminum or magnesium alloy structure. Layers of non-conductive materials like plastic and ceramics may also be affixed to a conductive layer using the fastener made from a compatible material that extends through a pilot hole.