Abstract: A method for use in efficiently joining together multiple workpieces to inhibit establishment of weld material in unwanted areas. The method uses a hybrid shaping-and-energizing system having a shaping tool and an ultrasonic horn. The method positions the hybrid shaping-and-energizing system proximate a workpiece, uses the shaping tool to form at least one recess in the proximate workpiece, and applies weld energy to the proximate workpiece using the ultrasonic horn. The recess is formed and the weld energy applied such that molten workpiece material becomes disposed within the recess, thereby inhibiting formation of weld material in the unwanted areas.

Abstract: An assembly and method for minimizing an overlap of a composite member riveted to another member includes a first member having a first overlap area and a second member having a second overlap area. The overlap areas of the first and second members are in direct contact, thereby forming an overlapped region. The overlapped region may be thicker than the sum of the individual members. The second member includes an end defining a projection in the overlapped region. The rivet is disposed through the first member and at least partially through the second member in the projection, thereby interlocking the second member to the first member. The projections include a curved symmetrical body defining an apex. The rivet extends through the body such that a line extending from the center axis of the rivet is perpendicular to a tangent extending through the apex of the projection.

Abstract: A spin fastening system includes a first member and an adhesive layer applied to the first member. A second member is positioned in contact with the adhesive layer. At least a portion of the adhesive layer is cured after the second member is positioned in contact with the adhesive layer to render at least the portion of the adhesive layer substantially rigid. At least one spin fastener is inserted successively through each of the second member, the cured portion of the adhesive layer, and the first member.

Abstract: A resistance spot welding method can be used to join polymeric and metallic workpieces together and includes the following steps: (a) placing an electrically conductive coating between a polymeric workpiece and a metallic workpiece, wherein the metallic workpiece has a textured surface facing the polymeric workpiece; (b) piercing the polymeric workpiece with first and second electrically conductive pins of a welding electrode assembly; (c) applying electrical energy to the first and second electrically conductive pins so that an electrical current flows through the first electrically conductive pin, the electrically conductive coating, and the second electrically conductive pin in order to at least partially melt the polymeric workpiece and the electrically conductive coating, thereby forming a weld pool; and (d) cooling the weld pool to form a solid weld nugget in order to establish a mechanical interface lock between the solid weld nugget and the textured surface.

Abstract: A method of riveting a first substrate and a second substrate with a rivet includes delivering a first ultrasonic pulse to a respective exterior surface of the first substrate at a predefined target area, via an ultrasonic device. The first ultrasonic pulse is configured to soften the first substrate at a first softening temperature. The method includes attaching a crust layer on a rivet head of the rivet. A second ultrasonic pulse is delivered to the predefined target area to soften the crust layer at a second softening temperature, via the ultrasonic device. A surface profile of the crust layer is fashioned via compression of a horn inner cavity of the ultrasonic device over the crust layer. The crust layer is cooled to harden into a seal configured to prevent entry of moisture between the rivet and the respective exterior surface of the first substrate, thereby reducing galvanic corrosion.

Abstract: A custom weld-repair tool, for use in repairing a discrepant weld between workpieces, including an extended portion and a cavity adjacent the extended portions. The discrepant weld includes an insufficient primary portion and the tool is configured to, when the extended portion is in contact with a proximate one of the workpieces, channel welding energy, received at or generated at the tool, to the proximate workpiece via the extended portion, to form or enlarge a weld at a periphery of the primary portion or directly adjacent the primary portion.

Abstract: An apparatus and processes for protecting an ultrasonic welding horn (504) during welding of polymeric composites, use a thin separator, or membrane (502) configured to transfer high-frequency acoustic vibrations while keeping the horn (504) isolated from molten workpiece material. Systems and methods for welding polymeric composites, use a conductive mechanical intermediary, reducing cycle time, compensating for any surface unevenness, and improving weld accuracy and connection strength.

Abstract: Systems and methods to improve weld quality are described. For example, certain systems and methods described use weld quality monitoring as feedback to an ultrasonic welding process to improve weld quality. Still other systems and methods provide improvement to double sided and single sided ultrasonic welding through the use of selected multiple pulses.

Abstract: Systems and methods to improve weld quality are described. For example, certain systems and methods described use weld quality monitoring as feedback to an ultrasonic welding process to improve weld quality. Still other systems and methods provide improvement to double sided and single sided ultrasonic welding through the use of selected multiple pulses.

Abstract: Systems and methods to improve weld quality are described. For example, certain systems and methods described use weld quality monitoring as feedback to an ultrasonic welding process to improve weld quality. Still other systems and methods provide improvement to double sided and single sided ultrasonic welding through the use of selected multiple pulses.

Abstract: The present technology discloses methods for joining a first workpiece and a second workpiece through a heat stake, and products formed thereby. The first workpiece has an aperture configured to receive a stud positioned on a second workpiece. The system is formed by applying energy to the first workpiece using electrodes, which indirectly heats the stud, at least partially softening material of the stud. Pressure is then applied to the softened material of the stud, and causing the material to form according to a predetermined geometry. After pressure is released, the stud forms a stake forming an interlocked joint connecting the workpieces.

Abstract: Systems and method are provided for joining components. A pin may have a head, and a stem extending from the head. The stem may have a tapered section. A collar may have a shank with a through-hole. Another tapered section may be formed by the shank so that a tapered surface of the tapered section faces into the through-hole. The pin and the collar may be configured so that the stem is received in the through-hole. The tapered sections mate together, and the tapered surface contacts the tapered section of the stem.

Abstract: A method for use in efficiently joining together multiple workpieces to inhibit establishment of weld material in unwanted areas. The method uses a hybrid shaping-and-energizing system having a shaping tool and an ultrasonic horn. The method positions the hybrid shaping-and-energizing system proximate a workpiece, uses the shaping tool to form at least one recess in the proximate workpiece, and applies weld energy to the proximate workpiece using the ultrasonic horn. The recess is formed and the weld energy applied such that molten workpiece material becomes disposed within the recess, thereby inhibiting formation of weld material in the unwanted areas.

Abstract: A process, for locating a welding energy director, for effective welding together of multiple workpieces at an area of the director. The director includes positioning a workpiece arrangement in preparation to make approaches, for locating the director, wherein the workpiece arrangement includes a proximate workpiece of the multiple workpieces, a distal workpiece, and the welding director positioned therebetween. The process also includes performing a sub-routine comprising moving a locating implement toward the proximate workpiece. The routine also includes determining whether a push-back force, being received at the locating implement from the workpiece, indicates that the locating implement has been lowered to a local terminal point.

Abstract: A joining device includes a nose, a punch, and a die anvil. The punch is coaxially slidable within the nose. A fastener is arranged within the nose and is coaxially slidable within the nose and movable by the punch. An ultrasonic vibration is focused through the die anvil to a zone on a material assembly arranged thereon for heating the zone. The punch is configured to drive the fastener outwardly from the nose and into the material assembly at the zone.

Abstract: A two-part mechanical fastener comprising an elongated body with a bore slidably carrying a mandrel adapted to interferingly engage the body is described. The fastener body has one or more protuberances on its exterior surface. In an aspect, the protuberances form a thread. The fastener is adapted to form an opening in, and penetrate, a stack of two or more workpieces. To secure the workpieces in the workpiece stack and form a robust joint, the fastener body is deformed by the mandrel, expanding the body, so that a body end engages a surface of the workpiece stack and the one or more protuberances are brought into engagement with the walls of the opening. Methods of using such a fastener to secure non-ferrous or polymer-based sheet-like workpieces to one another are disclosed.

Abstract: A method of riveting a first substrate and a second substrate with a rivet includes delivering a first ultrasonic pulse to a respective exterior surface of the first substrate at a predefined target area, via an ultrasonic device. The first ultrasonic pulse is configured to soften the first substrate at a first softening temperature. The method includes attaching a crust layer on a rivet head of the rivet. A second ultrasonic pulse is delivered to the predefined target area to soften the crust layer at a second softening temperature, via the ultrasonic device. A surface profile of the crust layer is fashioned via compression of a horn inner cavity of the ultrasonic device over the crust layer. The crust layer is cooled to harden into a seal configured to prevent entry of moisture between the rivet and the respective exterior surface of the first substrate, thereby reducing galvanic corrosion.

Abstract: A method of resistance spot welding a steel workpiece and an aluminum or aluminum alloy workpiece together includes several steps. In one step a workpiece stack-up is provided. The workpiece stack-up includes a steel workpiece and an aluminum or aluminum alloy workpiece. Another step involves providing a first welding electrode that confronts the aluminum workpiece, and providing a second welding electrode that confronts the steel workpiece. The first welding electrode has an electrode body and an insert that functions to limit or eliminate heat flux into the electrode body. Other steps of the method involve bringing the first and second welding electrodes into contact with opposite sides of the workpiece stack-up and resistance spot welding the stack-up.

Abstract: A spin fastening system includes a first member and an adhesive layer applied to the first member. A second member is positioned in contact with the adhesive layer. At least a portion of the adhesive layer is cured after the second member is positioned in contact with the adhesive layer to render at least the portion of the adhesive layer substantially rigid. At least one spin fastener is inserted successively through each of the second member, the cured portion of the adhesive layer, and the first member.

Abstract: A method for joining a plurality of workpieces includes providing a rotating drive tool. A fastener is secured to the drive tool. The drive tool is then rotatably driven such that a distal end of the fastener rotates against a surface of the plurality of workpieces. A heated material zone is then generated on the plurality of workpieces as caused by friction from the rotation of the fastener against the surface of the plurality of workpieces. The distal end of the fastener is rotatably and axially driven through the heated material zone. Finally, the drive tool is removed from the fastener, such that when the heated material zone cools, a portion of the heated material zone is fused to the fastener.