Abstract: A variable gage blank is formed from a set of components joined by a joining process. The set of components include a web, a first flange, and a second flange. The components have respective thicknesses. The first flange and the second flange may be modified to include a transition region with a variable thickness that terminates on an edge having a thickness substantially similar to a thickness of the web.

Abstract: A technique for producing tailored metal blanks composed of two pieces having different thickness involves modifying at least one piece to include a transition region. A thickness of a modified piece changes over the transition region so that a substantially similar thickness is provided along a joint of the two pieces. The two pieces, subsequent to modification, are joined via a welding process, which may be a laser welding process or a friction stir welding process.

Abstract: A technique for creating a weld along a joint. A method begins by positioning a first edge of a first member proximate to a second edge of a second member to form the joint, wherein the joint is to be welded along the length from a first position on the joint to a second position on the joint. A clamping ring of a refill spot welding apparatus is placed to surround an unwelded portion of the length. The clamping ring contacts a top surface of the first member and a top surface of the second member. A first refill spot weld process is performed with the refill spot welding apparatus to join the first member and the second member at a first spot weld on the joint.