Abstract: A multi-height energy-directing device, for facilitating staged welding together of workpieces. The device includes multiple elements extending from a body, wherein the elements do not all have a same height. Each element of a first group of the elements has a first height while each element of a second group of the elements has a second height differing from the first height. The elements are configured to channel welding energy through the device in a predetermined manner. The predetermine manner includes channeling the energy through taller, primary, elements, of said elements, in an initial stage of the welding process, while passing none through shorter, secondary, elements, of said elements, in the initial stage.

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 disclosure relates to methods by which a warped workpiece is reconfigured in a pre-determined manner to reduce a separation between the warped workpiece and a joining workpiece. The warped workpiece is reformed/reshaped, prior to joining, by softening material of the warped workpiece through application of a predetermined amount of energy at or near warping and using a directional force applied to a first surface of the warped workpiece, thus reducing a separation space at a joining interface of the warped workpiece and joining workpiece.

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: 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: 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: Methods of crack avoidance during resistance spot welding are provided. The compressive stress from the spot welding is distributed across an electrode assembly having an enlarged footprint. The electrode assembly includes a conductive core and a non-conductive cover. The delivery of current through the electrode assembly is localized to the conductive core.

Abstract: The present disclosure relates a rivet body, including a rivet head and a rivet shank, composed of a different material than a mandrel used for insertion into a workpiece(s), the mandrel including a mandrel shaft and a mandrel cap. The rivet body receives the mandrel shaft, including the mandrel cap, through the rivet shank. The mandrel shaft is received by the installation tool, which rotates the rivet body, and the mandrel cap locally deforms workpieces(s) through friction riveting to install the rivet body. During the friction riveting, the fast-rotating rivet body is pushed into the workpiece(s) causing local deformation/melting where the mandrel cap contacts the workpiece(s). The mandrel cap creates a cavity which progresses through an upper surface and a lower surface of the workpiece(s).

Abstract: A method includes forming a first pocket in a first sheet of material and a second pocket in a second sheet of material, pressing the first pocket and the second pocket together at a nonlinear interface, and welding material of the first pocket and the second pocket at the interface.

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 resistance spot welding system can join two polymeric workpieces and includes a power supply. The power supply has a positive terminal and a negative terminal. The resistance spot welding system further includes a welding electrode assembly electrically connected to the power supply. The welding electrode assembly includes a housing, a first electrically conductive pin and a second electrically conductive pin. The first and second electrically conductive pins both protrude from the housing. The first electrically conductive pin is electrically connected to the positive terminal of the power supply, and the second electrically conductive pin is electrically connected to the negative terminal of the power supply. The second electrically conductive material is electrically insulated from the first electrically conductive pin. The first and second electrically conductive pins are at least partly made of a material having a hardness ranging between 50 HRC and 70 HRC.

Abstract: Disclosed are wire feeding devices having a wire feeding pipe and a feed unit that pushes a wire through the wire feeding pipe. Either the wire feeding pipe comprises a two- way shape-memory alloy or the wire feeding pipe has an attached, over-lapping, or inserted extension segment extending beyond a distal end of the wire feeding pipe, the extension section comprising a two-way shape-memory alloy. The two-way shape-memory alloy has a trained shape in a martensite phase having a passageway for a wire and a trained shape in an austenite phase having a passageway for a wire that is narrower than the martensite phase passageway. When heated to the austenite phase of the two-way shape-memory alloy, the narrower passageway applies pressure to straighten a bend in the wire.

Abstract: An apparatus for resistance welding with a welder includes a heat pipe including a hollow tube and a weld electrode fitted around a portion of the heat pipe. The weld electrode and heat pipe are conductively coupled to conduct heat across an inner surface of the weld electrode.

Abstract: A method is provided for the projection electric resistance welding of a component to a laminated metal member. The laminated metal member is comprised of top and bottom metal sheets adhered together by a polymer layer provided between the top and bottom metal sheets. A plurality of projections is provided on the component and the projections extend toward the top metal sheet of the laminated metal. Force is applied to the component and the projections have a pointed shape so that the projections pierce through the top metal sheet and contact the bottom metal sheet. Weld current is then applied to flow through the projections so that the projections are electric resistance welded to both the top and bottom metal sheets.

Abstract: A method is provided for adhesively bonding together a pair of metal sheets to form a laminated sheet metal assembly. A coating of heat curable adhesive is placed on the bottom sheet. The top sheet is placed on top of the coating of adhesive. The stacked metal sheets are then placed between a pair of electrodes. One of the electrodes has a pointed projection that pierces through at least the adjacent sheet and into the adhesive. Electrical current is then conducted between the electrodes so that current flows through the projection to create electric resistance heating and thereby cure the adhesive. The electrodes can be rotating rollers and the metal sheets are fed between the rollers. The electrodes can provide heating and curing of the adhesive in a spot surrounding the pointed electrode and then the remaining uncured adhesive can be cured during later heating of the laminated assembly.

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 ultrasonic welding system, for welding together two workpieces wherein at least one of the workpieces includes a polymeric composite, comprising an energy applicator positioned along an action axis so that, in operation, ultrasonic vibrations transmitted from the energy applicator during a welding routine, are transmitted to the workpieces generally at and/or adjacent the axis. The system also includes a primary, course-control, actuator positioned along action axis so that a first load, output by the primary actuator, acts along the system action axis. The system further comprises a secondary, fine-control, actuator positioned along the system action axis so that a second load output, by the secondary actuator, acts along the axis. And the system comprises a controller for providing first command signals and second command signals to the primary actuator and second actuator to control them to effect loads on the workpieces, during the welding routine and along the axis.

Abstract: A hybrid shaping-and-energizing system, for use in efficiently joining together multiple workpieces while inhibiting establishment of weld material in unwanted areas. The system including a shaping tool configured to form at least one recess in a proximate workpiece of the workpieces to be joined, and a weld-energy applicator connected to the shaping tool and configured to apply weld energy to the proximate workpiece. The recess is formed, and weld energy applied, so that molten workpiece material becomes disposed within the recess, thereby inhibiting formation of weld material in any undesired position.