Abstract: A method of joining electrical connections together includes evaluating at least one weld joint between at least two substrates, determining mismatch between the at least two substrates, and welding the at least two substrates together with a multi-step welding process. The multi-step welding process includes compensating for mismatch between the at least two substrates by welding on both sides but not overlapping a joint line between the at least two substrates with a first welding step and increasing melt volume and penetration depth of a weld between the at least two substrates with a second welding step.

Abstract: A method of joining at least two substrates includes welding the at least two substrates together with a multi-step welding process. The multi-step welding process includes: reducing a mismatch between the at least two substrates by melting on both sides of the at least two substrates to form a melted portion that does not overlap a joint line between the at least two substrates with a first welding step; and increasing melt volume and penetration depth of the melted portion between the at least two substrates with a second welding step.

Abstract: A method of joining electrical connections together includes evaluating at least one weld joint between at least two substrates, determining a mismatch between the at least two substrates, and welding the at least two substrates together with a multi-step welding process. The multi-step welding process includes compensating for the mismatch between the at least two substrates by welding on both sides but not overlapping a joint line between the at least two substrate with a first welding step and increasing melt volume and penetration depth of a weld between the at least two substrates with a second welding step.

Abstract: A value stream method of manufacturing a plurality of vehicle structural rails includes feeding a coil of aluminum alloy sheet into a roll forming machine and forming a tubular shape with a seam, bobbin tool-friction stir welding the seam of the tubular shape and forming a welded tubular shape with a welded seam, cutting the welded tubular shape into a plurality of tubular sections, tube bending each of the plurality of tubular sections and forming a plurality of bent tubular sections, and hydroforming each of the plurality of bent tubular sections and forming a plurality of structural rails. The coil of aluminum alloy sheet may or may not be pre-treated and/or lubricated.

Abstract: An inspection probe and system for inspecting a welded or brazed joint includes a housing having an internal cavity and opposed tapered standoffs disposed at a distal end portion of the housing. Distal ends of the opposed tapered standoffs define pivot surfaces, and the opposed tapered standoffs are spaced apart to define a secondary enclosure. A plurality of transducer elements are disposed within the internal cavity of the housing and a primary coupling medium made of a flexible, semi-solid material is secured between the opposed tapered standoffs. A signal processing module is in communication with a data acquisition unit, which is in communication with the transducer elements. The inspection probe is rotated across the joint, data from the transducer elements is communicated to the signal processing module, and reconstructed and corrected images obtained at different angles from the transducer elements are stitched to generate an inspection image.

Abstract: A method of joining electrical connections together includes evaluating at least one weld joint between at least two substrates, determining mismatch between the at least two substrates, and welding the at least two substrates together with a multi-step welding process. The multi-step welding process includes compensating for mismatch between the at least two substrates by welding on both sides but not overlapping a joint line between the at least two substrates with a first welding step and increasing melt volume and penetration depth of a weld between the at least two substrates with a second welding step.

Abstract: A method of joining electrical connections together includes evaluating at least one weld joint between at least two substrates, determining a mismatch between the at least two substrates, and welding the at least two substrates together with a multi-step welding process. The multi-step welding process includes compensating for the mismatch between the at least two substrates by welding on both sides but not overlapping a joint line between the at least two substrate with a first welding step and increasing melt volume and penetration depth of a weld between the at least two substrates with a second welding step.

Abstract: A system and method of welding a workpiece. A predetermined current may be applied through electrodes that engage the workpiece. A resistance profile may be generated based on the predetermined current. A weld profile may be selected based on the resistance profile. The weld profile may then be executed to weld the workpiece.

Abstract: A method is disclosed for dressing a resistance stop welding (RSW) tip and a tip dresser apparatus. According to the method, a circumferential shoulder is cut to a predetermined depth from a distal end of the RSW tip. The shoulder is cut in the side wall to provide a reduced radius side wall and a reduced radius distal end on the RSW tip. The depth of dressing the distal end of the RSW tip is controlled by providing a stop that engages a step formed in the side wall formed by the circumferential shoulder. The tip dresser apparatus includes a first cutting blade retained by a first holder that cuts a step into the side wall to a predetermined depth. A second cutting blade retained by a second holder cuts a radiused surface on the distal end until the stop engages the step.

Abstract: A high capacity aluminum spot welding trans-gun includes a pair of opposed electrodes, a weld control that controls the operation of the trans-gun, and a transformer that regulates the voltage to the trans-gun having a primary input voltage and secondary output voltage. A liquid-cooled high voltage primary conductor electrically connects the weld control to the transformer primary input and a low voltage secondary conductor electrically connects the transformer secondary output to the welding gun to energize the opposed electrodes.

Abstract: An aluminum welding system includes a welding machine configured to weld a workpiece with an aluminum nugget and a measurement device configured to measure an attribute of at least one of the aluminum nugget and a welding process. The system further includes a processing device configured to output a weld quality signal representing a quality of an aluminum weld based at least in part on the attribute measured. A method includes measuring an attribute of at least one of an aluminum nugget forming a joint of a workpiece and a welding process, determining a quality of an aluminum weld based at least in part on the attribute measured, and outputting a weld quality signal representing the determined quality.

Abstract: A welding electrode assembly is provided including a mounting adapter, a shank and an electrode cap. The electrode assembly includes a shortened shank reinforced over a larger percentage of its length by the mounting adapter and electrode cap. Further, the cap includes a larger or longer working end allowing for the completion for more spot weld operations before requiring replacement.

Abstract: A method is disclosed for dressing a resistance stop welding (RSW) tip and a tip dresser apparatus. According to the method, a circumferential shoulder is cut to a predetermined depth from a distal end of the RSW tip. The shoulder is cut in the side wall to provide a reduced radius side wall and a reduced radius distal end on the RSW tip. The depth of dressing the distal end of the RSW tip is controlled by providing a stop that engages a step formed in the side wall formed by the circumferential shoulder. The tip dresser apparatus includes a first cutting blade retained by a first holder that cuts a step into the side wall to a predetermined depth. A second cutting blade retained by a second holder cuts a radiused surface on the distal end until the stop engages the step.

Abstract: An aluminum welding system includes a welding machine configured to weld a workpiece with an aluminum nugget and a measurement device configured to measure an attribute of at least one of the aluminum nugget and a welding process. The system further includes a processing device configured to output a weld quality signal representing a quality of an aluminum weld based at least in part on the attribute measured. A method includes measuring an attribute of at least one of an aluminum nugget forming a joint of a workpiece and a welding process, determining a quality of an aluminum weld based at least in part on the attribute measured, and outputting a weld quality signal representing the determined quality.

Abstract: A high capacity aluminum spot welding trans-gun includes a pair of opposed electrodes, a weld control that controls the operation of the trans-gun, and a transformer that regulates the voltage to the trans-gun having a primary input voltage and secondary output voltage. A liquid-cooled high voltage primary conductor electrically connects the weld control to the transformer primary input and a low voltage secondary conductor electrically connects the transformer secondary output to the welding gun to energize the opposed electrodes.

Abstract: A system and method of welding a workpiece. A predetermined current may be applied through electrodes that engage the workpiece. A resistance profile may be generated based on the predetermined current. A weld profile may be selected based on the resistance profile. The weld profile may then be executed to weld the workpiece.

Abstract: An ultrasonic welding apparatus and method for detaching or effecting release of an ultrasonic welding tool stuck or attached to a weldment. The method includes the step of utilizing a mechanism mounted adjacent to the ultrasonic welding tool to hold the weldment in position during welding and/or while the ultrasonic welding tool is withdrawn and, if necessary, using the mechanism to detach the weldment from the ultrasonic welding tool. The method contemplates providing a twist, rotary or axial motion to one of the ultrasonic welding tool or weldment to effect release of the ultrasonic welding tool. The apparatus may include a clamp member having a distinct clamping area or pad located adjacent to the sonotrode or anvil of the ultrasonic welding tool. The clamp mechanism provides vibration control, noise mitigation, and a more uniform boundary condition during welding and facilitates part release upon the completion of the welding process.

Abstract: An ultrasonic welding apparatus and method for detaching or effecting release of an ultrasonic welding tool stuck or attached to a weldment. The method includes the step of utilizing a mechanism mounted adjacent to the ultrasonic welding tool to hold the weldment in position during welding and/or while the ultrasonic welding tool is withdrawn and, if necessary, using the mechanism to detach the weldment from the ultrasonic welding tool. The method contemplates providing a twist, rotary or axial motion to one of the ultrasonic welding tool or weldment to effect release of the ultrasonic welding tool. The apparatus may include a clamp member having a distinct clamping area or pad located adjacent to the sonotrode or anvil of the ultrasonic welding tool. The clamp mechanism provides vibration control, noise mitigation, and a more uniform boundary condition during welding and facilitates part release upon the completion of the welding process.

Abstract: The present invention is a disassembly apparatus and method for disassembling a workpiece having at least two layers joined together by welding or other bonding processes at bonding points. The method includes the steps of securing the workpiece into a fixture to prevent movement of one of the layers. The apparatus includes a sonotrode and a holding device. The method further includes moving the sonotrode to contact the workpiece to apply a predetermined amount of contact pressure to the workpiece. The sonotrode in contact with the layer on a side opposite the anvil is then vibrated at a predetermined frequency until the layers become disassembled. An apparatus for performing the method is also disclosed.

Abstract: The present invention is a disassembly apparatus and method for disassembling a workpiece having at least two layers joined together by welding or other bonding processes at bonding points. The method includes the steps of securing the workpiece into a fixture to prevent movement of one of the layers. The apparatus includes a sonotrode and a holding device. The method further includes moving the sonotrode to contact the workpiece to apply a predetermined amount of contact pressure to the workpiece. The sonotrode in contact with the layer on a side opposite the anvil is then vibrated at a predetermined frequency until the layers become disassembled. An apparatus for performing the method is also disclosed.