Abstract: An apparatus and corresponding methods are disclosed to resistively spot weld a stack of sheet metal having a plurality of sheets of sheet metal. In one embodiment, a method includes contacting a first welding tip to a first side of the stack and contacting a second welding tip to a second side of the stack, the second side comprising a thinnest exterior sheet of the stack, the second welding tip including a contacting surface area less than the first welding tip; applying a squeeze pressure to the stack; and applying a current to the stack by applying a first current pulse for a first duration followed by applying a second current pulse for a second duration longer than the first duration and with a lower current than a current of the first current pulse.

Abstract: A non-destructive weld testing system for testing spot welds includes a weld monitoring tool monitoring at least one weld characteristic of the spot welds and generating weld data based on the at least one weld characteristic; a weld analysis tool analyzing the weld data to determine a weld quality of each spot weld based on analysis criteria; and a non-destructive weld testing tool configured to test spot welds. The weld testing system causes the weld testing tool to target testing of spot welds determined by the weld analysis tool to have a weld quality beyond a threshold weld quality. The weld testing tool may be a robot-mounted phased array transducer generating weld test data based on testing results and provides feedback to the weld analysis tool correlating to the weld test data. The weld analysis tool updates the analysis criteria based on the weld test data.

Abstract: A non-destructive weld testing system for testing spot welds includes a weld monitoring tool monitoring at least one weld characteristic of the spot welds and generating weld data based on the at least one weld characteristic; a weld analysis tool analyzing the weld data to determine a weld quality of each spot weld based on analysis criteria; and a non-destructive weld testing tool configured to test spot welds. The weld testing system causes the weld testing tool to target testing of spot welds determined by the weld analysis tool to have a weld quality beyond a threshold weld quality. The weld testing tool may be a robot-mounted phased array transducer generating weld test data based on testing results and provides feedback to the weld analysis tool correlating to the weld test data. The weld analysis tool updates the analysis criteria based on the weld test data.

Abstract: An apparatus for adaptive welding is provided. The apparatus includes an arc welding robot having a repositionable arc welding gun. The arc welding robot is configured to position the arc welding gun at a location of a joint formed at an interface of at least a first workpiece and a second workpiece. The apparatus further includes a thermographic imager that is configured to measure a temperature of at least one of the first workpiece and the second workpiece at the location. The apparatus also includes a controller that is in signal communication with the arc welding robot and the thermographic imager. The controller is configured to select a weld schedule for forming a weld at a location based at least in part on the temperature measured with the thermographic imager and a joint profile of the location before the weld is formed.

Abstract: An electrical resistance spot welding tip for joining a plurality of aluminum alloy workpieces includes a cylindrical body extending along a central axis defined through the body between a first end and an opposing second end of the cylindrical body. A spherically domed central region is formed at the first end of the cylindrical body. The spherically domed central region has an outer boundary defining a diameter of the spherically domed central region. An annular outer ring is positioned coaxially about the spherically domed central region. The annular outer ring has an end surface defined in a plane perpendicular to the central axis. A distance between a point on the spherically domed central region defined at the central axis and the end surface of the annular outer ring is dependent on a thickness of each of the plurality of aluminum alloy workpieces.

Abstract: An apparatus and corresponding methods are disclosed to resistively spot weld a stack of sheet metal having a plurality of sheets of sheet metal. In one embodiment, a method includes contacting a first welding tip to a first side of the stack and contacting a second welding tip to a second side of the stack, the second side comprising a thinnest exterior sheet of the stack, the second welding tip including a contacting surface area less than the first welding tip; applying a squeeze pressure to the stack; and applying a current to the stack by applying a first current pulse for a first duration followed by applying a second current pulse for a second duration longer than the first duration and with a lower current than a current of the first current pulse.

Abstract: An apparatus for adaptive welding is provided. The apparatus includes an arc welding robot having a repositionable arc welding gun. The arc welding robot is configured to position the arc welding gun at a location of a joint formed at an interface of at least a first workpiece and a second workpiece. The apparatus further includes a thermographic imager that is configured to measure a temperature of at least one of the first workpiece and the second workpiece at the location. The apparatus also includes a controller that is in signal communication with the arc welding robot and the thermographic imager. The controller is configured to select a weld schedule for forming a weld at a location based at least in part on the temperature measured with the thermographic imager and a joint profile of the location before the weld is formed.

Abstract: An intelligent stepper system and method for controlling weld current in a welding operation includes a welder welding a plurality of spot welds in succession and a controller incrementally increasing the weld current by a first fixed amount or percentage at each of the plurality of spot welds. Weld spatter is sensed at each of the plurality of spot welds and weld current is decreased by a second fixed amount or percentage when weld spatter is sensed.

Abstract: A system and method for performing one-sided resistance spot welding on parts to be welded. The system uses a resistance spot welding device that transfers electric welding current through a consumable welding spike to a localized spot on the parts to be welded. The welding spike is pressed against one side of the parts to be welded by a weld electrode during the spot welding process. The consumable welding spike is preferably melted and absorbed into the melt pool produced by the electric welding current.

Abstract: A multiple-chamber inflator (10) for a vehicle occupant protection system. The inflator (10) includes a housing (12) having a first end and a second end, and a divider disc (18) positioned in an interior of the housing (12) intermediate the housing ends to form a first (primary) propellant chamber (20) and a second (secondary) propellant chamber (22) within the interior of the housing (12). The divider (18) has a first surface (59) in communication with the first propellant chamber (20), a second surface (57) in communication with the second propellant chamber (22), and at least one aperture (60) extending between the first and second surfaces to provide fluid communication between the first propellant chamber (20) and the second propellant chamber (22). A pressure-resistant shim (62) fabricated from a low-melting point material is fixed on the divider first surface (59) over the at least one aperture (60) to block the aperture.

Abstract: An inflator (10) is provided for supplying gas to a vehicle airbag from the combustion of pyrotechnic materials. The inflator (10) has a two-piece inflator body (12) held together by crimping the body components, rather than welding. An igniter assembly (18) is positioned in a bore (22) in an upper piece (14) of the inflator body and is held in place with a press-fit interface and an adhesive seal. The upper piece (14) of the inflator body is rounded, increasing its strength, and fits partially into the lower piece (16). A booster tube is unnecessary, making the inflator lighter in weight and increasing available volume for propellant.

Abstract: A gas generator or inflator 10 preferably contains a housing 12 formed from welding a cap 14 and a base 16 in nested and coaxial relationship. Welding a first wall 15 of the cap 14 with an adjoining and substantially coextensive second wall 17 of the base 16 forms a structural girth. An annulus 36 is preferably formed centrally within the cap 14 thereby providing a seat for an igniter mount 22. An igniter mount 22 is fixed within the annulus 36, and houses an igniter 18 fixed therein.