Abstract: A method of single sided spot welding includes the steps of providing a metal tube having a convex surface portion and providing a metal sheet for welding to the metal tube. The method also includes the steps of contacting the metal sheet with the convex surface portion of the metal tube and contacting the metal sheet with a welding electrode. The method further includes the steps of supplying power to the welding electrode for melting metal and solidifying the molten metal to form a weld nugget between the metal sheet and the metal tube.

Abstract: A method of single sided, spot welding includes the steps of providing a metal tube having a convex surface portion and providing a metal sheet for welding to the metal tube. The method also includes the steps of contacting the metal sheet with the convex surface portion of the metal tube and contacting the metal sheet with a welding electrode. The method further includes the steps of supplying power to the welding electrode for melting metal and solidifying the molten metal to form a weld nugget between the metal sheet and the metal tube.

Abstract: A method is disclosed for inserting an end of a first tubular member into a complementary end of a second tubular member and attaching (e.g., welding) the adjacent surfaces of the inserted ends in a tight peripheral bond. In the method, a substantially continuous protrusion is formed in either the first or second member. Thereafter, the first and second tubular members are placed relative to each other such that a current may be passed through the protrusion and a seal may be formed, thereby joining the members.

Abstract: An apparatus allows a robot arm located in from of a body panel to create a spot weld joint located inboard of and behind an edge of the panel. A bracket fixed to the wrist of the robot arm has an open side wide and deep enough to reach around and behind the panel edge, so that an electrode fixed to the bracket can be aligned with the desired weld location. Then, a power cylinder pulls the bracket inward until the electrode hits the weld point, under tension. The electrode then fires to create the joint, and is retracted and moved. The robot arm and wrist remain entirely in front of the panel, and no access holes in the panel are needed to reach the remote weld point.