Abstract: A sheet metal assembly includes first and second resistance weldable metal sheets having flanges extending from the sheets. The flanges overlap in parallel for a dimension. A resistance weldable metal shim is disposed between the flanges and extends to the outer edges thereof. A weld joins the metal sheets through the shim. The shim increases the mechanical strength of the assembly. The increase in mechanical strength from the shim allows for reductions to the flange width. As a result, a lighter assembly of equivalent strength is produced.

Abstract: A sheet metal assembly includes first and second metal sheets having flanges extending from the sheets. The flanges overlap in parallel for a dimension. A shim is disposed between the flanges and extends to the outer edges thereof. A weld joins the metal sheets through the shim. The shim increases the mechanical strength of the assembly. The increase in mechanical strength from the shim allows for reductions to the flange width. As a result, a lighter assembly of equivalent strength is produced.

Abstract: A laser is used to melt portions of first and adjacent workpieces to form a weld. As the laser melts the workpieces, a powdered metal is injected into the molten metal pool. The powdered metal improves the strength of the weld by providing additional weld volume to bridge any preexisting gaps between the workpieces. The molten metal is then cooled to form a weld between the workpieces. For welding galvanized steel or metals with coatings or alloy materials having a lower vaporizing temperature, a powdered metal is used that reacts with the lower temperature metal to form an alloy that avoids vaporization during welding, thereby reducing weld porosity and weld spatter.

Abstract: A laser is used to melt portions of first and adjacent workpieces to form a weld. As the laser melts the workpieces, a powdered metal is injected into the molten metal pool. The powdered metal improves the strength of the weld by providing additional weld volume to bridge any preexisting gaps between the workpieces. The molten metal is then cooled to form a weld between the workpieces. For welding galvanized steel or metals with coatings or alloy materials having a lower vaporizing temperature, a powdered metal is used that reacts with the lower temperature metal to form an alloy that avoids vaporization during welding, thereby reducing weld porosity and weld spatter.