Abstract: A weld inspection system is adapted to inspect a weld of a work product via thermographic technology. The weld inspection system includes a heat source assembly, a thermal imaging camera, and a controller. The heat source assembly is adapted to sequentially direct a plurality of heat pulses upon the work product from varying perspectives and within a pre-determined time period. Thea thermal imaging camera is configured to thermally image the weld over the pre-determined time period and collect thermal imaging data of heat dissipation from the work product. The thermal imaging data is associated with the weld and the plurality of heat pulses. The controller is configured to control the heat source assembly and the thermal imaging camera. The controller includes a processor configured to receive and transform the thermal imaging data into a binary image for evaluation of the weld.

Abstract: A computer software product adapted for use in a weld inspection system is executed by a processor and is stored in an electronic storage medium of the weld inspection system adapted to facilitate the inspection of a weld of a work product. The computer software product includes a first module and a combination module. The first module is configured to transform first and second raw thermal images, associated with respective first and second heat pulses of at least a portion of the work product having the weld, into respective first and second binary images. The combination module is configured to transform the first and second binary images into a combined binary image for the reduction of noise.

Abstract: A rotor stack assembly includes multiple plates each including multiple elongated slots each oriented radially outward from a longitudinal central axis of each plate toward an outer perimeter wall of the plate. Multiple openings are each positioned proximate to one of the slots and directed outwardly through the outer perimeter wall. Multiple runners individually extend through the plate and individually open into one of opposed ends of each of the slots. Multiple bars of a conductive material are each extended through aligned ones of the slots of each of the multiple plates.

Abstract: A lithium ion battery pouch cell is disclosed that includes a copper-free negative terminal tab in which at least a joining region of an exterior portion of the negative terminal tab is aluminum or nickel-coated aluminum. In this way, the negative terminal tab of the lithium ion battery pouch cell may be welded to a common aluminum bus bar along with a positive terminal tab of another lithium ion battery pouch cell, or the negative terminal tab and the positive terminal tab of the two lithium ion battery pouch cells may be directly welded together in the absence of a common bus bar. Because the negative terminal tab does not include copper, the difficulties inherent in welding aluminum and copper, such as the formation of brittle Al—Cu intermetallic compounds, can be avoided. Lithium ion battery packs that include the disclosed lithium ion battery pouch cell are also disclosed.

Abstract: A method for manufacturing an electro-mechanical device includes creating a plurality of substrates using a first additive manufacturing process. Each of the substrates includes a polymeric material. The substrates include a first substrate and a second substrate. The first substrate includes a first main body and defines a protrusion extending from the first main body. The second substrate includes a second main body and a recess defined in the second main body. The method includes coupling the first substrate to the second substrate by inserting the protrusion into the recess such that the protrusion elastically deforms to an elastically averaged configuration. The protrusion and the recess together form an elastic averaging coupling. The method includes creating a plurality of electrically conductive components using a second additive manufacturing process and then coupling the electrically conductive components to at least one of the substrates.

Abstract: A rotor stack assembly includes multiple plates each including multiple elongated slots each oriented radially outward from a longitudinal central axis of each plate toward an outer perimeter wall of the plate. Multiple openings are each positioned proximate to one of the slots and directed outwardly through the outer perimeter wall. Multiple runners individually extend through the plate and individually open into one of opposed ends of each of the slots. Multiple bars of a conductive material are each extended through aligned ones of the slots of each of the multiple plates.

Abstract: A method of resistance spot welding a steel workpiece and an aluminum or aluminum alloy workpiece, and a welding electrode used therein. In one step of the method a workpiece stack-up is provided. The workpiece stack-up includes a steel workpiece and an aluminum or aluminum alloy workpiece. Another step of the method involves contacting the aluminum or aluminum alloy workpiece with a weld face of the welding electrode. The welding electrode has a body and an insert. The insert is composed of a material having an electrical resistivity that is greater than an electrical resistivity of the material of the body. The weld face has a first section defined by a surface of the insert and has a second section defined by a surface of the body. Both the first and second sections make surface-to-surface contact with the aluminum or aluminum alloy workpiece amid resistance spot welding.

Abstract: A modular stator includes a first stator module and a second stator module. The first stator module includes a plurality of first coil end regions and a plurality of first junctions. The second stator module includes a plurality of second coil end regions and a plurality of second junctions. The first stator module and the second stator module are joined at the plurality of first junctions and the plurality of second junctions.

Abstract: A rotor for an induction motor includes a first shorting end ring, a second shorting end ring, and a plurality of conductor bars. Each conductor bar has a first end and a second end and is coated with an electrically conductive material. The first end of each conductor bar is in electrical and mechanical contact with the first shorting end ring, and the second end of each conductor bar is in electrical and mechanical contact with the second shorting end ring. The conductive material is disposed between each conductor bar and the respective shorting end rings.

Abstract: A cutting tool that can simultaneously cut and restore asymmetric weld face geometries of two welding electrodes that are subject to different degradation mechanisms is disclosed along with a method of using such a cutting tool during resistance spot welding of workpiece stack-ups that include dissimilar metal workpieces. The cutting tool includes a first cutting socket and a second cutting socket. The first cutting socket is defined by one or more first shearing surfaces and the second cutting is defined by one or more second shearing surfaces. The first shearing surface(s) and the second shearing surface(s) are profiled to cut and restore a first weld face geometry and a second weld face geometry, respectively, that are different from each other upon receipt of electrode weld faces within the cutting sockets and rotation of the cutting tool.

Abstract: A method of forming a weld interface between a first workpiece and a second workpiece includes arranging a reactive braze material at a first joining surface of the first workpiece. The reactive material is selected to react upon being heated to a temperature below the solidus temperature of the first and second workpieces to form a liquid-containing reaction product. Furthermore, an assembly is prepared of the first workpiece and the second workpiece with the first joining surface of the first workpiece and a second joining surface of the second workpiece separated by the reactive material. The second workpiece is then heated with a first laser beam following a first path and with a second laser beam following a second path.

Abstract: A method of forming a rotor includes isolating a bridge area of an electrical steel lamination. The bridge area is disposed between a first portion of the electrical steel lamination and a second portion of the electrical steel lamination that is adjacent to the first portion. Each of the first portion, the second portion, and the bridge area has an initial hardness, and the electrical steel lamination has an initial magnetic permeability. After isolating, the method includes hardening only the bridge area so that the bridge area has a treated hardness that is greater than the initial hardness. Concurrent to hardening, the method includes decreasing the initial magnetic permeability at only the bridge area.

Abstract: A method of joining together adjacent overlapping copper workpieces by way of resistance spot welding involves providing a workpiece stack-up that includes a first copper workpiece and a second copper workpiece that lies adjacent to the first copper workpiece. The faying surface of the first copper workpiece includes a projection that ascends beyond a surrounding base surface of the faying surface and makes contact, either directly or indirectly, with an opposed faying surface of the second copper workpiece. Once provided, a compressive force is applied against the first and second copper workpieces and an electric current is passed momentarily through the first and second copper workpieces. The electric current initially flows through the projection to generate and concentrate heat within the projection prior to the projection collapsing. This concentrated heat surge allows a metallurgical joint to be established between the first and second copper workpieces.

Abstract: A welded assembly and a method of reaction metallurgical welding are disclosed. The assembly includes a first metallic workpiece and a second metallic workpiece attached together by at least two overlapping weld joints. The overlapping weld joints are reaction metallurgically joined (RMJ) weld joints, and each overlapping weld joint overlaps with the other overlapping weld joint by 10-75%. The method of welding includes providing a reactive material between and in contact with the first and second workpieces. In a first position, the workpieces and the reactive material are pressed together, heated, and held between first and second tools to form a first RMJ weld joint between the workpieces. Then, in a second position, the workpieces are pressed together, heated, and held between the tools to form a second RMJ weld joint that overlaps with the first RMJ weld joint.

Abstract: A stack assembly having a battery tab with a localized weld and method of making the same is disclosed. The assembly is made by a process including the steps of arranging a plurality of battery tabs into a stack assembly; providing a resistive coating on at least one of the interior surfaces and the exterior surfaces of the battery tabs; and resistive heating the stack assembly. The resistive coating is a nickel-phosphorous (Ni—P) alloy containing 5 to 7 weight percent phosphorus. Resistive heating includes reacting the Ni—P alloy with an electric current to generate concentrated heat localized between adjacent battery tabs such that the Ni—P alloy undergoes solid-state bonding with the Cu in the first batter tab.

Abstract: A welding electrode for use in resistance spot welding an assembly of overlying metal workpieces that includes an aluminum alloy workpiece is disclosed. The welding electrode includes a body, a convex weld face at one end of the body, and ringed protrusions that project outwardly from the convex weld face. The ringed protrusions are positioned to make contact with, and indent into, a surface of the aluminum alloy workpiece when the convex weld face is pressed against the aluminum alloy workpiece during a spot welding event. When brought into contact with the surface of the aluminum alloy workpiece, the ringed protrusions disrupt the oxide film present on the aluminum alloy workpiece surface, which improves the spot welding process.

Abstract: A resistance spot welding method may involve spot welding a workpiece stack-up that includes a steel workpiece and an aluminum alloy workpiece. A pair of opposed welding electrodes are pressed against opposite sides of the workpiece stack-up with one welding electrode contacting the aluminum alloy workpiece and the other welding electrode contacting the steel workpiece. The welding electrodes are constructed so that, when an electrical current is passed between the electrodes and through the workpiece stack-up, the electrical current has a greater current density in the steel workpiece than in the aluminum alloy workpiece to thereby concentrate heat within a smaller zone in the steel workpiece. Concentrating heat within a smaller zone in the steel workpiece is believed to modify the solidification behavior of the resultant molten aluminum alloy weld pool in a desirable way.

Abstract: A method of joining a first metal workpiece substrate and a second metal workpiece substrate by way of reaction metallurgical joining involves passing a pulsating DC electrical current through the metal workpiece substrates and a reaction material disposed between confronting faying surfaces of the workpiece substrates. The electrical current comprises a plurality of current pulses that generally increase in applied current level.

Abstract: A method of joining together adjacent overlapping copper workpieces by way of resistance spot welding involves providing a workpiece stack-up that includes a first copper workpiece and a second copper workpiece that lies adjacent to the first copper workpiece. The faying surface of the first copper workpiece includes a projection that ascends beyond a surrounding base surface of the faying surface and makes contact, either directly or indirectly, with an opposed faying surface of the second copper workpiece. Once provided, a compressive force is applied against the first and second copper workpieces and an electric current is passed momentarily through the first and second copper workpieces. The electric current initially flows through the projection to generate and concentrate heat within the projection prior to the projection collapsing. This concentrated heat surge allows a metallurgical joint to be established between the first and second copper workpieces.

Abstract: An arc welding/brazing process is disclosed that is useful to join together a first copper piece and a second copper piece without damaging more heat-sensitive materials that may be located nearby is disclosed. The arc welding/brazing process includes using a non-consumable electrode wire, which electrically communicates with a weld control in a straight polarity orientation, to strike an arc across a gap established between a leading tip end of the electrode wire and the first copper piece. The current that flows through the arc when the arc is established heats the first copper piece such that the first copper piece becomes joined to a second copper piece. The joint between the first copper piece and the second copper piece may be an autogenous weld joint or a braze joint.