Abstract: A first metal member is contacted with a second metal member. A metal fastener is provided including a core and a cladding disposed upon the core. The fastener is driven through the first member and into the second member, inducing friction between the fastener, the first member and the second member for at least locally melting portions of the cladding, the first member and the second member to form a flowable material that solidifies and metallurgically bonds the fastener to the first member and the second member for attaching the members together.

Abstract: A method and apparatus for projection welding a metal fastener (e.g., a nut) to a metal member (e.g., a sheet) is disclosed. The apparatus includes a first electrical contact and a locator assembly having a second electrical contact. For welding the fastener to the member, the locator assembly aligns through-holes of the fastener and sheet and a current is passed through protrusions of the fastener. In turn, the protrusions are softened to bond with the member.

Abstract: A pogo welding apparatus especially for spot welding metal sheets at selected locations spaced away from their edges wherein the sheets are held in a temporary assembly with the selected locations engaged and separate programmable positioners move a primary (pogo) electrode and a backup electrode sequentially against opposite sides of the selected locations to spot weld the sheets at the selected locations in sequence. Various alternative programmable positioners, including robots of varying types, may be used to carry the electrodes. A multi head back-up electrode is adapted for efficient use of the apparatus and method in difficult to reach workpiece locations.

Abstract: A method and apparatus for riveting metal members, and particularly, metal sheets is disclosed. The apparatus includes a rivet assembly for driving rivets into stacked metal sheets and a die assembly for assisting in supporting the sheets during driving of the rivets and for assisting in securing the rivets to the sheets. The rivet assembly, the die assembly or both in combination provide energy to at least a portion of the metal sheets prior to riveting. In turn, the energy elevates the temperature of the portion of the sheets such that the rivets can be more effectively driven into the sheets and such that the sheets are fastened to each other with greater ease and consistency.

Abstract: A rivet and method for riveting metal members, and particularly, metal sheets is disclosed. The apparatus includes a rivet assembly for driving a piercing rivet into stacked metal sheets and a die for assisting in supporting the sheets during driving of the rivet and for assisting in securing the rivets to the sheets. The rivet of the invention includes an adhesive that is forced through passages in the rivet for assisting in fastening the rivet to the sheets and for assisting in fastening the sheets to each other with greater strength.

Abstract: A method and apparatus are provided for loosely attaching blind rivets to components of an assembly. The method includes attaching a rivet to an assembly while positioning the head at a predetermined clearance away from the adjacent one of the assembly components. One or both of the aligned openings in the components may be enlarged to leave radial clearance between the assembled rivet body and the enlarged openings. The apparatus includes a nose insert for use with or attachment to a rivet gun or attaching apparatus. The insert forms a stop engageable by a preformed rivet head to maintain a predetermined clearance between the rivet head and adjacent component when the rivet is attached to components forming an assembly.

Abstract: A first metal member is contacted with a second metal member. A metal fastener is provided including a top radially enlarged portion, a bottom radially enlarged portion and a shank portion intermediate the thicker portions for forming a circumferential groove about the axis and fastener. The fastener is driven through the first member and into the second member, inducing friction between the fastener, the first member and the second member for at least locally melting portions of the first member and the second member to form a flowable material that flows into the circumferential groove of the fastener and solidifies.

Abstract: A method of attaching metal members, including placing the metal members in contact with each other and fastening them with a metal fastener having a central axis wherein the metal fastener includes an elongated portion having a substantially constant cross-sectional area at any cross-section taken along a length of the elongated portion perpendicular to the axis of the fastener and includes a topographically varying outer surface. The fastener is driven through the metal sheet and into the metal substrate during rotation of the fastener thereby inducing friction between the fastener, the sheet and the substrate for locally melting the members to form a flowable material that solidifies for attaching the members, the flowable material and the fastener together.

Abstract: The method includes the steps of providing a first metal member and contacting the first metal member with a second metal member. A substantially cylindrical rotatable member is provided and is rotated while frictionally engaging it with the first metal member for locally heating and melting a portion of the first metal member, and penetrating the rotatable member through the first metal member. The rotatable member is rotated while frictionally engaging it with the second metal member for locally heating and melting a portion of the second metal member. A wire is fed through the axially extending passage and melted as it exits the axially extending passage. The resulting molten wire is mixed with the resulting molten metal of the first and second member, and solidified to form a joint.

Abstract: In attempting to reduce deformity when joining vehicle frame components, a riveting/brazing process has been proposed. This process includes joining tubular members, such as hydroformed parts, by cutting at least one flange into one end of a first body member, shaped in conformance with the surface of a second body member. Location holes are formed into each flange as well as into the surface of the second member in suitable alignment with each other. A brazing filler material is fixed into a side of the flange, usually within a pocket, intending to lie on the surface of the second member when the two structures are attached. The flange(s) are initially attached to the surface of the second member by means of a rivet to formed an actual vehicle body assembly. Heat is then applied to the assembly to form a brazed T-joint.

Abstract: A method and apparatus for clinching metal sheets is disclosed. The apparatus includes a punch assembly for stamping indentations into stacked metal sheets and a die assembly for assisting in supporting the sheets during stamping of the indentations and for assisting in forming the indentations. The punch assembly, the die assembly or both in combination provide energy to at least a portion of the metal sheets prior to stamping. In turn, the energy elevates the temperature of the portion of the sheets such that the indentations can be more effectively formed in the portion and such that the sheets are fastened to each other with greater strength.

Abstract: A pogo welding apparatus especially for spot welding metal sheets at selected locations spaced away from their edges wherein the sheets are held in a temporary assembly with the selected locations engaged and separate programmable positioners move a primary (pogo) electrode and a backup electrode sequentially against opposite sides of the selected locations to spot weld the sheets at the selected locations in sequence. Various alternative programmable positioners, including robots of varying types, may be used to carry the electrodes. A multi head back-up electrode is adapted for efficient use of the apparatus and method in difficult to reach workpiece locations.

Abstract: A method for electrical resistance welding thin metal sheets together is disclosed. In the method, a protrusion is formed upon a first sheet wherein the protrusion includes a planar circular surface and an annular sloping wall. Thereafter, electrodes pass an electrical current through the protrusion as the protrusion is contacted with a second metal sheet for electric resistance welding the first sheet to the second sheet.

Abstract: A method and apparatus are provided for loosely attaching blind rivets to components of an assembly. The method includes attaching a rivet to an assembly while positioning the head at a predetermined clearance away from the adjacent one of the assembly components. One or both of the aligned openings in the components may be enlarged to leave radial clearance between the assembled rivet body and the enlarged openings. The apparatus includes a nose insert for use with or attachment to a rivet gun or attaching apparatus. The insert forms a stop engageable by a preformed rivet head to maintain a predetermined clearance between the rivet head and adjacent component when the rivet is attached to components forming an assembly.

Abstract: A method and system for testing joints which join one member to another member are disclosed. The method and assembly are capable of non-destructively testing joints which join such members without damaging the members or the joints.

Abstract: A pogo welding apparatus especially for spot welding metal sheets at selected locations spaced away from their edges wherein the sheets are held in a temporary assembly with the selected locations engaged and separate programmable positioners move a primary (pogo) electrode and a backup electrode sequentially against opposite sides of the selected locations to spot weld the sheets at the selected locations in sequence. Various alternative programmable positioners, including robots of varying types, may be used to carry the electrodes.

Abstract: A pogo welding apparatus especially for spot welding metal sheets at selected locations spaced away from their edges wherein the sheets are held in a temporary assembly with the selected locations engaged and separate programmable positioners move a primary (pogo) electrode and a backup electrode sequentially against opposite sides of the selected locations to spot weld the sheets at the selected locations in sequence. Various alternative programmable positioners, including robots of varying types, may be used to carry the electrodes.

Abstract: A method for forming an electrical resistance weld between a metal tube and a metal sheet is disclosed. In the method, a plurality of generally circular protrusions having generally triangular cross sections is formed upon the sheet. Thereafter, electrodes are utilized to flex the tube, while an electrical current is generated for electric resistance welding the sheet to the tube.

Abstract: A method and apparatus for measuring the contact resistance at electrode-to-workpiece and workpiece-to-workpiece interfaces for spot welding simulations. A constant compressive load is applied through electrodes and workpieces to simulate a load applied during an actual resistance spot welding process. A discharging current circuit applies an initial high current of the order of 1.2 KA to electrodes and workpieces to break down contaminant films on surfaces of the workpieces. A relatively small constant current of about 2A is then applied to the electrodes and workpieces and the voltage across and the current flow through the electrodes and workpieces are measured. The contact resistance is determined from the measured voltage and current.