Abstract: An apparatus for adaptive welding is provided. The apparatus includes an arc welding robot having a repositionable arc welding gun. The arc welding robot is configured to position the arc welding gun at a location of a joint formed at an interface of at least a first workpiece and a second workpiece. The apparatus further includes a thermographic imager that is configured to measure a temperature of at least one of the first workpiece and the second workpiece at the location. The apparatus also includes a controller that is in signal communication with the arc welding robot and the thermographic imager. The controller is configured to select a weld schedule for forming a weld at a location based at least in part on the temperature measured with the thermographic imager and a joint profile of the location before the weld is formed.

Abstract: An electrical resistance spot welding tip for joining a plurality of aluminum alloy workpieces includes a cylindrical body extending along a central axis defined through the body between a first end and an opposing second end of the cylindrical body. A spherically domed central region is formed at the first end of the cylindrical body. The spherically domed central region has an outer boundary defining a diameter of the spherically domed central region. An annular outer ring is positioned coaxially about the spherically domed central region. The annular outer ring has an end surface defined in a plane perpendicular to the central axis. A distance between a point on the spherically domed central region defined at the central axis and the end surface of the annular outer ring is dependent on a thickness of each of the plurality of aluminum alloy workpieces.

Abstract: An apparatus for adaptive welding is provided. The apparatus includes an arc welding robot having a repositionable arc welding gun. The arc welding robot is configured to position the arc welding gun at a location of a joint formed at an interface of at least a first workpiece and a second workpiece. The apparatus further includes a thermographic imager that is configured to measure a temperature of at least one of the first workpiece and the second workpiece at the location. The apparatus also includes a controller that is in signal communication with the arc welding robot and the thermographic imager. The controller is configured to select a weld schedule for forming a weld at a location based at least in part on the temperature measured with the thermographic imager and a joint profile of the location before the weld is formed.