Abstract: The present disclosure provides a method that includes providing a first blank including an upper major surface, a lower major surface, and a plurality of side surfaces that connect the lower major surface to the upper major surface. The upper and lower major surfaces each includes a coating that includes aluminum, and the side surfaces are devoid of the coating. The method also includes forming an additive layer on at least one of the side surfaces that is devoid of the coating, and includes laser welding the first blank including the additive layer to a second blank, wherein a thickness of the additive layer is such that during the laser welding, the laser irradiates a material of the additive layer without irradiating the coating to form a weld pool that includes the material of the additive layer and does not include the aluminum of the coating.

Abstract: A method of soldering battery cell tabs to a conductor is provided. The battery cell tab and the conductor are made of a material independently selected from aluminum, copper, or nickel-plated copper. The method include preparing an assembly of the battery cell tabs and the conductor with a first joining surface of one battery cell tab face-to-face with a first joining surface of the conductor, at least one joining surface having a layer of solder thereon; pressing the assembly so that the facing joining surfaces engage the solder, and heating the solder to a temperature above a melting temperature of the solder in the absence of a fluxing agent while limiting the displacement of the joining surfaces to a predetermined value; and holding the joining surfaces against each other and solidifying the solder to form a soldered joint between the battery cell tabs and the conductor.

Abstract: A laminated sheet metal is comprised of a first sheet of metal and a second sheet of metal that are adhered together by a polymer layer core that is interposed between the two sheets and provides visco-elastic adhesion. The polymer layer has at least one region of a first polymer material that is selected for optimal viscous and elastic qualities by which to dampen the transmission of noise and vibration between the sheets, and at least one other region of a second polymer material that is selected for optimal adhesive qualities by which the sheets are optimally joined together against delamination. Thus the laminated sheet metal can be tailored to optimize the qualities that are desired for the manufacture of a particular product.

Abstract: Outer steel sheet-viscoelastic core laminates are often subject to corrosion in moisture-containing environments. Zinc-based alloys of aluminum, or of aluminum and magnesium, may be beneficially applied to the inner faces of the steel sheets or to both the inner and outer sheet faces. Substantially pure zinc coatings may be applied over the zinc-based alloys or over an otherwise bare outer steel sheet surface. Combinations of such zinc-based alloy coatings and substantially pure zinc coatings improve the corrosion resistance of the steel sheet-polymer core laminates while maximizing weldability and paintability.

Abstract: Two steel sheets joined face-to-face with a core layer form a laminated workpiece that may be shaped, for example, into automotive components. Depending on the nature of the core layer the laminated workpieces may be used for sound and vibration damping or as light weight structural panels. Before joining of the steel sheets, their facing surfaces may each be provided with a polymeric (organic or inorganic) corrosion resistant film that resists physical degradation such as tearing or scratching as the laminate is formed into a desired component shape. The pre-applied protective layer may also provide a bonding layer for the viscoelastic core or a structural core material. Conductive particles may be incorporated into the viscoelastic layer to assist in electrical resistance welding involving the laminated steel workpiece.

Abstract: A method of joining or repairing metal surface structures. Joinder and/or repair of metal or metal-polymer laminate panels may be carried out using so-called “cold metal transfer” gas metal arc welding techniques. Moreover, suitable zinc-copper-aluminum alloys may improve weldability, durability and strength. The reduced thermal input permits effective weld formation at the metal sheet layers without giving rise to temperature gradient sufficient to significantly damage the interior elements.

Abstract: A laminated sheet metal is comprised of a first sheet of metal and a second sheet of metal that are adhered together by a polymer layer core that is interposed between the two sheets and provides visco-elastic adhesion. The polymer layer has at least one region of a first polymer material that is selected for optimal viscous and elastic qualities by which to dampen the transmission of noise and vibration between the sheets, and at least one other region of a second polymer material that is selected for optimal adhesive qualities by which the sheets are optimally joined together against delamination. Thus the laminated sheet metal can be tailored to optimize the qualities that are desired for the manufacture of a particular product.

Abstract: A method for laminating metal sheets together with a first polymer selected for its adhesive characteristics and a second polymer selected for its viscoelastic characteristics. One of the first sheets of metal or second sheets of metal is fed across a first engraved roller having recesses that carry the first polymer and deposit the first polymer onto only selected regions of the sheet of metal. One of the first and second sheets of metal is across a second engraved roller having recesses that carry the second polymer and deposit the second polymer onto only selected regions of the sheet of metal. And then the first and second sheets of metal are married together so that the first polymer and the second polymer are engaged between the first and second sheets in different regions, and the polymers are cured to thereby attach the sheets together as a laminated metal sheet.