Abstract: A method for monitoring the presence of an adhesive between two metal workpieces includes measuring the depth of indentation made by electric resistance weld electrodes by measuring the advance of the weld electrodes, and comparing the measured depth of indentation with the depth of indentation that is known to occur when the presence of the adhesive between the metal workpieces minimizes the shunting of weld current and thereby affects the depth of indentation. If the adhesive is absent, a supplemental electric resistance weld is made to compensate for the absent adhesive. The invention is applicable to both adhesive bonding, where only adhesive is used to attach the workpieces, and weldbonding, where an electric resistance weld is made atop a layer of adhesive.

Abstract: A method of controlling an indentation depth of an electrode into a metal substrate during formation of a weld includes selecting a weld force, current, duration, minimum indentation depth, and maximum indentation depth, contacting the substrate with the electrode to apply the force to the substrate, supplying the current to the electrode to initiate formation of the weld according to a first condition in which the depth is less than the minimum, a second condition in which the depth is greater than or equal to the minimum and less than or equal to the maximum, and a third condition in which the depth is greater than the maximum, and comparing the depth, minimum, and maximum. For the first condition, duration is changed. For the second condition, each of the force, current, and duration is maintained until the weld is substantially formed. For the third condition, current ceases to be supplied.

Abstract: A stator for an electric motor includes a stator coil including a wire pair with respective ends that are joined with a ring. The ring is positioned around the wire pair and joined to the wire pair by a metal joining process.

Abstract: A method of weld-bonding a plurality of workpieces to produce an improved peel joint, includes the formation of an adhesive layer and a weld nugget, and the securing of an adhesive cover relative the workpieces during bonding. The method is operable to partially prevent the migration of fluid adhesive material during construction, and to transfer at least a portion of peel loads to the shear strength of the adhesive material in the produced joint. The method may also be performed utilizing other interconnection means such as clinching or riveting.

Abstract: A method for weldbonding together metal sheets includes applying adhesive on the surface of a first sheet and placing a second sheet atop the first sheet. The sheets are heated at a selected location to a high temperature forming a metallic weld nugget between the first sheet and the second sheet. The adhesive may be a heat curable adhesive that is cured by the heat, or the adhesive may be heated at ambient temperatures. One or both of the sheets is then cooled in the area surrounding the selected location of heating so that the high temperature needed to created the metallic weld nugget is prevented from transferring so far beyond the selected location as to overheat the adhesive layer and thereby degrade the quality of the adhesive bond.

Abstract: A method is provided for attaching a fastener to the inside wall of a member. The fastener may be a bolt or a nut having a shank and a shaped head with head portions radiating from the shank. A hole is made in the member and has a shape closely corresponding to the shape of the head. The head of the fastener is inserted into the shaped hole and the fastener is reoriented so that the head engages with the inside walls of the member and therefore the fastener cannot be withdrawn. Electric current is applied to the fastener and the member to bond the head to the inside wall of the member either by heat curing an adhesive coating the head or by creating an electric resistance projection weld between the fastener head and the member.

Abstract: A method is provided for precisely positioning and joining first and second sheet panels. A first hole is extruded in the first panel with an annular upstanding wall surrounding the first hole. The first hole has a diameter to fit closely over the locating pin of a support. A second hole is formed in the second panel and has a diameter to fit closely over the annular upstanding wall of the first panel. A bond is created between the first and second panels adjacent to the annular upstanding wall, so that the annular upstanding wall protects the locating pin from being fouled by the bonding material. The bond may be either an adhesive bond or an electric resistance weld or both an adhesive bond and an electric resistance weld and the annular upstanding wall acts as a dam to protect the locating pin from the adhesive or weld splatter.

Abstract: Methods and apparatus are provided for the detection of conditions indicative of a wind pressure pulsation within the passenger cabin of a vehicle, and for the reduction of the intensity of the pressure pulsation via automatic window repositioning. The apparatus comprises vehicle sensors for detection of a pressure pulsation condition, controllers to process sensor data and issue commands, and power-operated vehicle windows.

Abstract: A method of joining workpieces includes rotating a friction stir rivet via a mandrel and driving the rivet into the workpieces causing frictional heating between the rivet and the workpieces and causing the materials of the workpieces to soften, thereby providing a fiction stirred displaceable path for the rivet to traverse, and driving the rivet along the displaceable path until the rivet mandrel pierces through the workpieces and a cap of the rivet is seated against the workpieces. Subsequent to seating the cap, further rotation of the mandrel is stopped and the workpieces are allowed to cool and harden. An axial load is then applied to the mandrel sufficient to provide mechanical loading between the rivet body and the workpieces. A resultant volume of displaced material from the workpieces is fixedly attached to the workpieces, thereby avoiding the creation of a potentially detachable slug of the displaced material.

Abstract: A monitoring device monitors an apparatus that clinches together sheet metal panels. In particular, a die assembly positioned on one side of the panels has a button forming die cavity defined by an anvil at the bottom of the die cavity and a plurality of radially moveably die blades at the side of the cavity. A plunger is positioned on the other side of the panels and registers with the die assembly so that linear displacement of the plunger plastically deforms the panels axially into the die assembly to engage with the anvil and then further linear displacement of the plunger will then deform the panels radially outward as permitted by the outward radial movement of the moveable die blades. Transducers measure the linear displacement of the plunger, the radial outward displacement of the radially moveable die blades, and the magnitude of the axial force applied against the anvil.

Abstract: A closure assembly with a shape memory polymer seal is provided for use with a vehicle. The closure assembly includes a frame member configured for attachment to the vehicle body to selectively transition from a closed position to an open position. The seal structure includes a base portion elongated along and attached to a peripheral edge of the frame member or the vehicle body, and a flexible contact portion extending integrally from the base portion and configured for sealing communication with an opposing surface. A thermally-activated smart material (TASM), namely a shape memory polymer member, is disposed inside a cavity within the contact portion. A thermoelectric device is in thermal communication with the TASM, and is characterized by a thermal differential when current flows therethrough. The TASM is activated in response to the thermal differential of the thermoelectric device, thereby altering at least one physical property of the TASM.

Abstract: Method and apparatus is provided for monitoring the installation of a blind rivet to attach together top and bottom members. The blind rivet installation tool includes a housing having an anvil seated on the rivet head. A collet is reciprocable within the tool housing and carries jaws for gripping the mandrel of the blind rivet. Retraction of the jaws by the collet displaces the jaws and the mandrel axially and causes the mandrel head to axially collapse and radially expand the hollow shank of the blind rivet into engagement with the bottom member so that the rivet attaches the top member and the bottom member. A cut off tool is actuated by an actuator to cut off the mandrel flush with the rivet head. Transducers and a process controller monitor the installation process and actuate the cut off blade upon determining that the blind rivet is properly installed.

Abstract: A method is provided for welding a laminated metal sheet to a workpiece. The laminated metal sheet includes an outer metal sheet and an inner metal sheet bonded together by a polymer material that impedes the flow of weld current. A punch is applied against the outer metal sheet and driven through the laminated metal sheet to create a hole and also create an annular metallic burr that bridges across the polymer material layer between the outer metal sheet and the inner metal sheet. A weld electrode is positioned against the outer metal sheet at the punched hole and weld current is conducted through the first annular metallic burr to create an electric resistance weld between the laminated metal and the workpiece.

Abstract: A friction stir nut is disclosed. The friction stir nut includes a body, a cap, and an anti-rotation feature. The body has an elongated cylindrical shank extending between a first end and a second end, the cap being disposed at the second end, and the anti-rotation feature being disposed at the cap and/or an outer surface of the body. The body and cap have a blind axial hole extending from the first end to the second end, the first end being blind and the second end being open. The outer surface of the first end has a flat surface oriented substantially perpendicular to the axis of the shank, and the body has a cylindrical wall thickness suitable for receiving internal threads. In response to a mandrel tool friction stir welding the friction stir nut to a workpiece and then being extracted, uniform internal threads result at the body. The anti-rotation feature bonds to the workpiece by metallurgical bonding and/or mechanical bonding.

Abstract: A dispensing apparatus for dispensing adhesive includes an adhesive source and a dispensing member. The dispensing member is movably attached to the adhesive source. A dispensing nozzle is located on the dispensing member to dispense adhesive onto a component. A heating element is also located on the dispensing member to heat the component. Finally, a roller element is located on the dispensing member to apply pressure to the adhesive.

Abstract: A fastener is provided for attachment to a workpiece by a friction stir process. The fastener includes a base having an underside adapted to seat upon the workpiece and a fastener portion attached to the top side of the base. An anchor portion projects from the underside of the base and is adapted to be rotated and advanced at high speed and inserted into the workpiece by friction stirring of the workpiece. The anchor portion is embedded in the workpiece upon cooling of the workpiece. The anchor portion has an indent in the surface thereof enabling the softened stirred material to flow into the indent and thereby mechanically capture the anchor portion within the solidified workpiece.

Abstract: A method of repairing and a repaired friction stir welded assembly is disclosed. The friction stir welded assembly repair may include the steps of: drilling a hole through a discrepant portion of the friction stir welded assembly; sliding a mandrel head and a tubular rivet body of a rivet assembly through the hole; seating a rivet head and an adhesive/sealer washer against one of the first workpiece and the second workpiece, with the adhesive/sealer washer located between portions of the rivet head and body and the friction stir welded assembly; pulling a mandrel to cause the mandrel head to create an upset portion of the rivet body engaging the friction stir welded assembly; and curing the adhesive/sealer washer.

Abstract: An enhanced head-and-neck restraint system is provided for use with a vehicle having a passenger compartment with a seat assembly and a safety belt assembly mounted therein. The restraint system includes first and second collar straps each having an inflatable cushion integrated thereto. A first end of each collar strap is attached to a headrest portion of the seat assembly to transition between a retracted position, in which the collar straps are substantially inside the headrest portion, and a use position, in which each collar strap attaches to a belt webbing of the safety belt system. A fluid dispensing apparatus is in fluid communication with the inflatable cushions, and operable to selectively transition the inflatable cushions from a non-expanded state to an expanded state when the collar straps are in the use position.

Abstract: A staple for attaching together first and second metal sheets is made of a length of round wire bent at the ends to form spaced apart depending metal legs, each having a metal piercing point at the end thereof adapted to pierce completely through the first sheet and at least partially through the second sheet and also adapted to spread the legs further apart during the piercing to a spread position in which the legs are anchored within the metal sheets and thereby attach the metal sheets together. The metal piercing points each having an outside bevel surface on the outside of the leg, an inside bevel surface on the inside of the leg, and a blunt end surface between the inside and outside bevel surfaces.

Abstract: An improved fusion welding system having a heating unit and welding device is adapted for increasing the efficiency of welding a plurality of workpieces. The system preferably presents a single-sided process, and includes first and second electrode wheels operable to heat a portion of the workpieces to a minimum temperature, and a translatable laser cooperatively configured to form a continuous weld within the heated portion. The preferred system provides the advantages of laser welding, such as precision, while enabling weld production at lower laser power outputs or faster welding speeds than conventional laser welding systems.