Abstract: An ultrasonic resistance welding apparatus 10 contains a resistance spot welding apparatus 15, a first electrode 16 and a vibrable second electrode 18, the vibrable second electrode 18 in operable communication with an ultrasonic transducer 12, whereby the ultrasonic transducer 12 selectively imparts vibratory energy to the vibrable second electrode 18 based on signals from a controller 32. The vibrable second electrode 18 may be tuned or designed to resonate within 2.5% of an operating frequency of the ultrasonic transducer 12. During operation of the welding apparatus 10, a tip 19 of the second vibrable electrode 18 may be positioned at an anti-nodal point 38 of the vibratory energy and the vibrable second electrode 18 may be attached to the resistance spot welding apparatus 15 at a nodal plane 36 of the vibratory energy. A process for employing the apparatus 10 is also presented.

Abstract: An example method for joining metals is described herein. The method can include forming an intermediate joint between a light metal member and a metal insert, where the intermediate joint is formed using a solid state welding process. The method can also include forming a primary joint between the light metal member and a high strength steel member, where the primary joint is formed using a welding process that produces coalescence at a temperature above the melting point of the light metal member and/or the high-strength steel member.

Abstract: An example method for joining metals is described herein. The method can include forming an intermediate joint between a first structural member and a foil member, where the intermediate joint is formed using a solid state welding process. The method can also include forming a primary joint between the first structural member and a second structural member, where the primary joint is formed using a welding process that produces coalescence at a temperature above the melting point of the first structural member or the second structural member.