Abstract: A laser welding head capable of producing a plurality of beams that are proficient in providing a unique keyhole. The welding head is movable through a plurality of positions relative to substrates that enables the plurality of beams to engage the substrates in a manner that welds the substrates in a variety of stack-up positions. A welding method using the welding head is also provided.

Abstract: A method for welding includes providing a pair of substrates with no gap between them. The welding process uses lasers that are movable through a locus of points relative to the substrates and each other to weld the substrate together. The movable lasers assist in controlling a formation of a weld keyhole that assists in expelling gases that develop during the welding process.

Abstract: A laser-welding apparatus may include a laser source, an incoming laser beam produced by the laser source, and a beam splitter that splits the incoming laser beam to form a leading beam and a trailing beam. A first focusing lens may focus the leading beam and a second focusing lens may focus the trailing beam to form a trailing-beam pattern on a workpiece. The trailing-beam pattern may include a crescent-shape having arms and a tail portion.

Abstract: A method for welding includes providing a pair of substrates with no gap between them. The welding process uses lasers that are moveable through a locus of points relative to the substrates and each other to weld the substrate together. The moveable lasers assist in controlling a formation of a weld keyhole that assists in expelling gases that develop during the welding process.

Abstract: A composite wheel and a method of manufacture is provided for a vehicle wherein the composite wheel has a first and second section mounted to an annular mount. At least one of the first wheel section and second wheel section is composed of a resin having at least one braided polymeric fiber. The first and second sections are each formed by folding the braided fiber into a preform and then injecting resin into a mold containing the preform. The first and second sections are then bonded to each other and the annular mount.

Abstract: A laser-welding apparatus may include a laser source, an incoming laser beam produced by the laser source, and a beam splitter that splits the incoming laser beam to form a leading beam and a trailing beam. A first focusing lens may focus the leading beam and a second focusing lens may focus the trailing beam to form a trailing-beam pattern on a workpiece. The trailing-beam pattern may include a crescent-shape having arms and a tail portion.

Abstract: A friction stir welding method where a friction stir welding device is moved through a plurality of points that form an essentially conical shape as the device engages substrates to be welded to form a mechanical interlocking structure at an interface between the substrates.

Abstract: A hybrid resistance heating/ultrasonic welding method is used to join substrates. The resistance heating sufficiently softens or melts the substrates at an interface, and an ultrasonic wave is used solid state bond the substrates at the interface. The hybrid method can be used for both spot welding as well as continuous welding.

Abstract: A laser welding head capable of producing a plurality of beams that are proficient in providing a unique keyhole. The welding head is movable through a plurality of positions relative to substrates that enables the plurality of beams to engage the substrates in a manner that welds the substrates in a variety of stack-up positions. A welding method using the welding head is also provided.

Abstract: A composite wheel and a method of manufacture is provided for a vehicle wherein the composite wheel has a first and second section mounted to an annular mount. At least one of the first wheel section and second wheel section is composed of a resin having at least one braided polymeric fiber. The first and second sections are each formed by folding the braided fiber into a preform and then injecting resin into a mold containing the preform. The first and second sections are then bonded to each other and the annular mount.

Abstract: A composite wheel and a method of manufacture is provided for a vehicle wherein the composite wheel has a first and second section mounted to an annular mount. At least one of the first wheel section and second wheel section is composed of a resin having at least one braided polymeric fiber. The first and second sections are each formed by folding the braided fiber into a preform and then injecting resin into a mold containing the preform. The first and second sections are then bonded to each other and the annular mount.

Abstract: A composite wheel and a method of manufacture is provided for a vehicle wherein the composite wheel has a first and second section mounted to an annular mount. At least one of the first wheel section and second wheel section is composed of a resin having at least one braided polymeric fiber. The first and second sections are each formed by folding the braided fiber into a preform and then injecting resin into a mold containing the preform. The first and second sections are then bonded to each other and the annular mount.

Abstract: A method and apparatus for in-situ laser welding of a hemmed joint are applicable for, among other things, production of vehicle doors having inner and outer panels to be joined. In a preferred method, the laser welding of a hemmed joint is carried out while a stable condition is maintained between the inner and outer panels. Locating members of a hemming machine are engaged with the metal sheets to be joined and a compressive force is applied to the panels. A plurality of welding units may be sequentially or simultaneously controlled by a computer. The apparatus includes a first portion for vertically locating the hemmed joint and a second portion for horizontally locating the hemmed joint.

Abstract: A laser welding system for welding sheets of material, such as automobile body parts, together includes a plurality of clamps. The system includes a fiber optic cable for each clamp having a first end coupled to a laser beam source and a second end coupled to the clamp for transmitting a laser beam from the laser beam source to the clamp. The system further includes a focusing head secured to each clamp and the second end of the cable for focusing the laser beam onto the material to be welded.