Abstract: Local heat may be generated through surfaces of sheet metal workpieces by supporting the workpiece(s) on a hard surfaced anvil and engaging the opposite surface of the workpiece with a rotating, and optionally translating, friction stir tool that is pressed against the work surface. Advantages are realized in friction stir processing (e.g. seam or spot welding) of such sheet metal workpieces by using an anvil with appreciable thermal conductivity, or a liquid cooled anvil body, to suitably cool the site(s) of the workpiece engaged by the friction stir tool to minimize or eliminate distortion of the workpiece.

Abstract: One side of a metal sheet is joined to a polymer layer by applying heat to a joining area on the opposite side of the metal. The heat flows through the thin metal to activate a thermoplastic material or heat setting polymer into a bond with the metal. The method can be used to bond the metal sheet to a plastic body or another metal member. It is preferred to use a friction or friction stir tool to heat the metal surface.

Abstract: One side of a metal sheet is joined to a polymer layer by applying heat to a joining area on the opposite side of the metal. The heat flows through the thin metal to activate a thermoplastic material or heat setting polymer into a bond with the metal. The method can be used to bond the metal sheet to a plastic body or another metal member. It is preferred to use a friction or friction stir tool to heat the metal surface.

Abstract: One side of a metal sheet is joined to a polymer layer by applying heat to a joining area on the opposite side of the metal. The heat flows through the thin metal to activate a thermoplastic material or heat setting polymer into a bond with the metal. The method can be used to bond the metal sheet to a plastic body or another metal member. It is preferred to use a friction or friction stir tool to heat the metal surface.

Abstract: A current collector plate, also called a bipolar plate, for a fuel cell includes two facing metal sheets with fluid channels for the fuel (often hydrogen) on the non-facing side of one sheet and fluid channels for air on the non-facing side of the other sheet. Such a plate is made by applying a patterned coating of particles of a soft and reactive metal to at least one of the sheets and rolling them together so that the soft metal particles deform and interact with the facing sheets to selectively join them at the patterned areas. Pressurized fluid is introduced between the sheets to expand non-bonded portions and define the fluid channels.

Abstract: A shape memory polymer workpiece is attached to a second workpiece. A face of the SMP workpiece is placed against an attachment surface of the second workpiece. The second workpiece has an attachment hole(s). The SMP workpiece is activated (e.g., heated) to a softening temperature and a portion extruded into the attachment hole of the facing surface of the second workpiece. The SMP piece is held while still heated against the second workpiece, the material flowing as result of the shape memory effect to form an attachment. As the SMP material cools while still under load its modulus increases fixing the attachment geometry. Reheating the attached parts without pushing them together reverses the process.

Abstract: The present invention provides an apparatus and improved method of friction stir spot welding that assures a predetermined bottom thickness and a reduction in variation in a series of resultant spot welds. The advantage of the present invention lies in that the plunge distance is controlled from the top plane of the anvil against which the bottom thickness is specified, and systematically adjusted to account for changing system parameters, such as, but not limited to, deflection and thermal expansion of the weld gun. The present invention also provides for improved and controlled weld quality through implementation of a dwell operation or dwell operations, whereby weld heat input is manipulated by causing the weld tool to dwell in a dwell region or at a desired depth or depths within the workpiece(s) for a predetermined time interval to achieve desired mechanical properties of the resultant weld joint.

Abstract: An apparatus and method is provided for hemming together a pair of panels and immediately sealing the hemmed joint against the intrusion of moisture. A tool mount is attached to a multi-axis manipulator such as a robot for moving the tool mount along the edge portions of the panels. A hemming roller is mounted on the tool mount and adapted to be moved along the edge portions of the panels by the multi axis manipulator to fold the flanged edge portion of the outer panel onto the edge portion of inner panel as the tool mount traverses the edge portions of the panels. A sealing mechanism is mounted on the tool mount adjacent to the hemming roller to seal the hemmed joint immediately after the flanged edge portion is folded onto the inner panel. The sealing mechanism may be a dispenser of adhesive sealer or a friction stir welder.

Abstract: A method is provided for welding together a tubular member of a first metal and a tubular member of a second metal that is dissimilar to the first metal. The method includes making a transition attachment by friction welding together end-to-end a first end of a rod of the first metal with a first end of a rod of the second metal. An arc weld welds together a second end of the rod of the first metal with the tubular member of the first metal. And another arc weld welds together a second end of the rod of the second metal to the tubular member of the second metal.

Abstract: The present invention is directed to additives for improved weldable composites. A metal composite structure (10) features two metal members (12)(14) sandwiching a viscoelastic layer (26) where the viscoelastic layer entrains carbide-forming, carbon trapping particles (28) configured and sized to provide an effective inhibitor to carbon migration from the viscoelastic layer during welding.

Abstract: A method for making a current collector plate includes providing a first sheet of material having a first bonding face and a first outer face. A second sheet of material is provided having a second bonding face and a second outer face. A work area is defined on at least one of the first bonding face and the second bonding face. The first and second sheets are bonded together at a bonding area which is different from the work area. The bonded first and second sheet is placed into a die having a pattern defining at least one flow channel. Fluid is injected between the first and second sheets thereby causing at least one of the first and second sheets to project outward at the work area causing at least one flow channel to be formed in the work area as defined by the die pattern.

Abstract: In an assembly of facing metal sheets separated by a polymer layer, welded metallurgical bonds are formed between the metal sheets by use of a friction stir weld tool. A rotating tool penetrates the first sheet, locally displaces the encountered portion of polymer film and penetrates into the second sheet. The affected metal of the two sheets is momentarily plasticized and stirred, and the plasticized metal of the two sheets combines to form a weld between the metal sheets. The interposed polymer film may be intended to serve as an adhesive or a vibration damping medium or the like. The facing metal sheets can be layers of facing laminated metal sheet structures that each comprise two metal sheets bonded by an adhesive interlayer.

Abstract: An anti-bonding material is placed in a desired pattern onto a first sheet of conductive material. A second sheet of conductive material is roll bonded with the first sheet of material. Fluid is injected between the bonded first and second sheets of material to expand the sheets of material at the desired pattern. A flow channel is formed at the desired pattern between the first and second sheet during fluid injection.

Abstract: An article for texturing an electrode having a tip hardness and a tip contour is disclosed. The article includes a plate having an upper surface and a lower surface, and an indentation in at least one of the upper and the lower surface. The indentation includes a textured surface having a plurality of asperities. The textured surface has a hardness greater than the tip hardness of the electrode. The texture of the textured surface is imprinted into the tip of the electrode in response to the tip of the electrode and the textured surface being pressed against each other.

Abstract: A surface of an article is heated and subjected to pressure by operation of a friction stir tool. The pressure of the face of the tool on the article surface, and the speed of rotation of the tool and of its progression along the surface of the article, are controlled to progressively hot-work a specified surface area. The face of the tool may be round and have a profiled, axially extending, smaller diameter pin for higher concentration of frictional heat and load and for plasticizing a surface layer of the workpiece. Such hot work may be applied for reducing surface porosity or for producing another change in the surface microstructure, or for effecting another change in surface material properties.

Abstract: One side of a metal sheet is joined to a polymer layer by applying heat to a joining area on the opposite side of the metal. The heat flows through the thin metal to activate a thermoplastic material or heat setting polymer into a bond with the metal. The method can be used to bond the metal sheet to a plastic body or another metal member. It is preferred to use a friction or friction stir tool to heat the metal surface.

Abstract: The present invention is directed to additives for improved weldable composites. A metal composite structure (10) features two metal members (12) (14) sandwiching a viscoelastic layer (26) where the viscoelastic layer entrains carbide-forming, carbon trapping particles (28) that provide an effective inhibitor to carbon migration from the viscoelastic layer during welding.

Abstract: The present invention is directed to improved weldable metal composites and methods. A metal composite structure (10) features two metal members (12) (14) sandwiching a viscoelastic layer (26) where the viscoelastic layer entrains electrically conductive particles (28) and a carbon extracting attractant layers (32) (34) to inhibit and/or prevent carbon migration and carbide formation during welding.

Abstract: A surface of an article is heated and subjected to pressure by operation of a friction stir tool. The pressure of the face of the tool on the article surface, and the speed of rotation of the tool and of its progression along the surface of the article, are controlled to progressively hot-work a specified surface area. The face of the tool may be round and have a profiled, axially extending, smaller diameter pin for higher concentration of frictional heat and load and for plasticizing a surface layer of the workpiece. Such hot work may be applied for reducing surface porosity or for producing another change in the surface microstructure, or for effecting another change in surface material properties.

Abstract: A current collector plate, also called a bipolar plate, for a fuel cell includes two facing metal sheets with fluid channels for the fuel (often hydrogen) on the non-facing side of one sheet and fluid channels for air on the non-facing side of the other sheet. Such a plate is made by applying a patterned coating of particles of a soft and reactive metal to at least one of the sheets and rolling them together so that the soft metal particles deform and interact with the facing sheets to selectively join them at the patterned areas. Pressurized fluid is introduced between the sheets to expand non-bonded portions and define the fluid channels.