Abstract: A method and apparatus for more efficiently fusing the straps of pre-formed terminal post members with plate lugs of a battery plate group utilizing a non-reusable, inexpensive plastic mold insert. The method includes positioning the battery plate group into an open top container with the lugs of the positive plates in one row and the lugs of the negative plates in another row, positioning the plastic insert into the container with the lugs of the plate group extending upwardly through the mold insert, positioning the terminal post members on the plastic mold insert with fingers of the straps thereof disposed between plate lugs of the respective rows, supplying additional unmelted lead into remaining spaces between the plate lugs, and heating, melting, and fusing the plate lugs, strap fingers, and added lead by induction heating to form interconnections between the positive and negative plates in the respective terminals.

Abstract: A grid casting mold for the casting of accumulator lead grids has two plates (11, 12) which can be placed against one another with a casting profile (13) or mold cavity complementary to the lead grid which is to be manufactured being formed in their confronting mold surfaces. The plates (11, 12) moreover have a base body (14, 15) which is provided at the profile side with a thermally insulating layer (16, 17) of high temperature fiber ceramic material which is coated on the side remote from the base body (14, 15) with a high wear resistant metal oxide (18, 19).

Abstract: Casting apparatus 10 includes a lead pot 11, a pump unit 12 and a mould block 13, having feed duct 14. The feed duct 14 communicates with the pump unit 12 by means of a supply passage 17, which is also connected to an overflow outlet 18, which can be closed by a dump valve 19. In normal operation the level of the lead in the feed duct is kept to a datum level 23 defined by the overflow. During `pouring` however the dump valve 19 is closed.

Abstract: Method and apparatus for joining lead battery parts (e.g., plate lugs, intercell connectors, terminals, etc.) together via a low resistance electrical coupling wherein substantially oxide-free, arc-melted, superheated molten lead is cast into a cavity between the parts. The parts are shielded from the arc while being bathed in a non-oxidizing atmosphere which is preferably formed from an ionizable, non-oxidizing gas heated by the lead-melting arc and spewed onto the parts along with the molten lead to provide additional heat thereto.

Abstract: Intercell fusing apparatus for use in a battery having flat tombstone type connections, each tombstone having a pair of vertically and horizontally outwardly extending portions of fusible material closely surrounding a vertical partition of electrically insulating material having a hole extending horizontally therethrough. It comprises a mold closely surrounding each pair of vertical portions of the tombstones and surrounding a partition portion above the hole, and a pair of interconnected coils preferably having double windings on each side of the partition to effect fusion of the tombstones within the mold when energized by a source of high frequency alternating current.

Abstract: A device, configured as a double mold, for casting terminal bars (straps) and terminal poles onto the lugs of a completely assembled plate group for electric storage batteries ensures optimum attachment of all of the lugs (both polarities) to the molten bar lead if the heat exchange between the bar lead and the dipped volume of each negative or positive lug is identical. This requirement is met by causing the negative and positive casting molds, together with their contents, to form thermally equivalent sections or blocks, which are equalized if necessary, by changing the dimensions (thickness) of the mold's walls. When the lugs are made of lead or a lead alloy, such a double mold also makes it possible, during a subsequent two-stage cooling process, to first allow the terminal poles to solidify, simultaneously, and to then allow the terminal bars to solidify, simultaneously.

Abstract: Method and apparatus for joining lead battery parts (e.g., plate lugs, intercell connectors, terminals, etc.) together via a low resistance electrical coupling wherein substantially oxide-free, arc-melted, superheated molten lead is cast into a cavity between the parts. The parts are shielded from the arc while being bathed in a non-oxidizing atmosphere which is preferably formed from an ionizable, non-oxidizing gas heated by the lead-melting arc and spewed onto the parts along with the molten lead to provide additional heat thereto.

Abstract: A method of casting metal straps on lugs of battery cell elements utilizes an electrically heatable mold having a strap cavity section and comprises introducing strap metal into the cavity section, conducting electrical current through the mold for heating the mold to a predetermined temperature in excess of the melting temperature of the strap metal, immersing the element lugs into the cavity, cooling the mold to a temperature below the solidification temperature of the strap metal and removing the element lugs from the cavity with straps cast thereon.

Abstract: A machine for casting battery grids in a continuous manner includes a rotary cylindrical drum in the outer peripheral surface of which the battery grid pattern is machined as a cavity. A shoe is arranged against an arcuate segment of the peripheral surface of the drum. An orifice slot in the shoe has an opening at the peripheral surface of the drum. Molten lead under superatmospheric pressure is directed into the orifice slot in an amount in excess of that required to fill the grid cavity on the drum through the opening in the orifice slot as the drum rotates. Means are provided in the shoe for maintaining the molten lead in the orifice slot in a highly fluid condition and for causing the lead filling the grid cavity to solidify rapidly as it advanced beyond the opening of the orifice slot.

Abstract: A method and apparatus for casting straps onto the plate lugs of battery cell elements. The apparatus includes a rotatably indexable table having a plurality of mold and element carrying stations which each are successively indexed through a plurality of operating stations, including an element loading station, an element lug alignment station, a molten-metal pouring station, a lug fluxing station, a casting station, a plurality of mold cooling stations, and an element unloading station. The mold of each table station is adapted for efficient and precisely controlled electrical resistance heating and forced-air cooling during each cycle of operation. In the illustrated embodiment, each table-station mold is successively heated from electrical sources at a plurality of operating stations upon indexing of the respective table station to such operating stations and is cooled by directing air through air-direction tubes mounted on each table station in close proximity to the respective mold.

Abstract: Members are welded together by indirect application of heat, as for welding internal battery posts for connecting groups of plates or terminal posts electrically, through the use of a plurality of heated elements simultaneously engaging posts to be welded together, and wherein the configuration of molten material is controlled as the weld cools, by the use of a templet. The elements are heated, preferably by application of open flame through a plurality of mixing systems for the fuel, with one system being provided for each heated element.

Abstract: For casting bridges having cell connecting flanges or and poles, respectiy, formed thereon or on the connecting lugs of lead storage battery grids use is made of molds in which mold troughs for liquid lead are developed. In order to increase the life, reduce the heating time and produce a crack-free connection of the grid lugs with the cell connecting flanges, the mold troughs of the mold are developed as individual mold segments which can be separated from each other and are assembled in a segment holder to form the entire mold. The individual mold segments can in particular for this be provided with a heat insulation for the mold trough.

Abstract: A side terminal lead alloy is provided which is a composition of lead, 3 wt-% antimony and 10 wt-% brass. The alloy is capable of use in conjunction with resistance welding techniques. The terminal created thereby exhibits sufficient structural integrity to permit a mechanical connection to be made directly thereto without any additional threaded inserts and exhibits sufficient electrical current conductivity to permit direct electrical connection thereto.

Abstract: Ultrasonically joining a plurality of discrete lead parts into a shaped, substantially metallurgically homogeneous joint. Preshaped lead pieces are placed in an ultrasonically vibrated mold for fusing the pieces and shaping the joint. The method is exemplified in the making of terminal posts for Pb-acid storage batteries.

Abstract: A machine for casting battery grids in a continuous manner includes a rotary cylindrical drum in the outer peripheral surface of which the battery grid pattern is machined as a cavity. A shoe is arranged against an arcuate segment of the peripheral surface of the drum. An orifice slot in the shoe has an opening at the peripheral surface of the drum. Molten lead under superatmospheric pressure is directed into the orifice slot in an amount in excess of that required to fill the grid cavity on the drum through the opening in the orifice slot as the drum rotates. Means are provided in the shoe for maintaining the molten lead in the orifice slot in a highly fluid condition and for causing the lead filling the grid cavity to solidify rapidly as it is advanced beyond the opening of the orifice slot.

Abstract: A tool for forming electrical interconnections between the terminal ends of storage cell plate lugs. This tool is particularly suited to forming such welds between the terminal ends of plate lugs which project through a cell case wall.

Abstract: Apparatus and method for injecting molten lead from a reservoir into a die mold cavity formed about an aperture in the wall of a plastic battery for casting lead-alloy battery terminal connectors. Batteries are positioned adjacent the molten lead reservoir of the apparatus and mold portions move together to hold the battery containers in a clamp-like action. Molten lead is die cast under pressure into the mold cavity in which a stainless steel threaded nut is positioned. The lead is forced through a heated chamber into a portion of the mold which may be water cooled. The mold is designed to allow venting of gases, thereby eliminating porosity; and the apparatus is designed to provide casting which is free of jagged projections in the sprue hole.

Abstract: A basket loader apparatus for a machine to cast commoning straps onto the positive and negative plate lugs of plate stacks used to form a multi-celled lead acid storage battery. As configured the apparatus is designed to hold a basket which contains said stacks and hold it during the casting operations. Prior to the start of said operation, the apparatus is further adapted to properly align the lugs for casting and further to enter the plates and the plastic separation which lie between them within the basket. The apparatus further includes vertical adjustment means so that plates of different size may be accommodated and vacuum cleaning means to remove fragments of lead sulfate paste and other foreign materials which might interfere with proper alignment of the plates within the basket.

Abstract: A machine for casting battery grids has a rotary drum, the pattern of the battery grid cavity being recessed into the outer periphery thereof. An arcuate shoe is fixedly positioned against the rotating drum in sliding contact with the outer peripheral surface thereof. The shoe has an internal passageway connected to an orifice slot which extends to the periphery of the drum. The orifice slot is connected at one end to a source of molten lead under pressure and at its other end to a return line. The molten lead in the orifice slot is under superatmospheric pressure. The rate of flow of the molten lead through the orifice slot is in excess of that required to fill the grid cavity.

Abstract: Battery plates are assembled into stacks forming positive and negative rows of lugs and the stacks are placed within the cells in a battery case. Molding channels are automatically formed around the positive and negative rows of lugs and molten lead alloy is automatically introduced into the molding channels to cast the straps and intercell connections simultaneously within the battery case.

Abstract: A composite mold construction for casting on the connector straps, posts, and terminals for lead acid electrical storage batteries wherein the mold cavity areas are alternately heated by direct flame on one face and then chilled by a coolant on their opposite face to freeze metal in the cavities without freezing molten metal flowing in adjacent flow channels. A plurality of mold cavity partition inserts are arranged to be interchangeable in the main mold assembly to enable a single mold assembly to be utilized for several arrangements of battery cells, strappings, and terminals. Thermal distortion of the mating parts is minimized to maintain the junctions between the insert and frame free of leaks by surface geometries which provide broad surfaces of contact drawn together by bolts securing the relatively thin inserts by tapped bores in the more massive primary portions of the mold assembly.

Abstract: In casting tubular-plate grids, a molten lead alloy is poured into a mold along the long side of the grid perpendicular to the grid rods. Temporary connectors joining adjacent grid rods are simultaneously cast. These connecting portions have a thickened cross-section in the middle and a constricted cross-section at their points of junction with the grid rods. In a subsequent operation, the connecting portions are punched out.

Abstract: Method of connecting a battery plate to a battery strap or post in a mould 50 provided with a number of separate mould cavities 51 arranged on each side of a duct or channel 52 for receiving molten lead. Between each mould cavity 51 and the channel 52 is positioned a weir or barrier 60 which determines the level of lead in each cavity. Lead pumped into the channel 52 flows into the cavities 51 over the weirs 60, the level of lead in channel 52 then drops below the top of the weirs 60 so that the level of lead in the cavities 51 falls to the level of the top of the weirs 60. The lugs 22 of battery plates 23 are then dipped into the lead in the cavities and the lead solidifies to form finished straps or posts. During the moulding process the lead is maintained in a molten state using heaters 78 and the mould cavities are cooled with a flow of cooling water.

Abstract: Method for injecting molten lead from a reservoir into a die mold cavity formed about an aperture in the wall of a plastic battery for casting lead-alloy battery terminal connectors. Batteries are positioned adjacent the molten lead reservoir of the apparatus and mold portions move together to hold the battery containers in a clamp-like action. Molten lead is die cast under pressure into the mold cavity in which a stainless steel threaded nut is positioned. The lead is forced through a heated chamber into a portion of the mold which may be water cooled. The mold is designed to allow venting of gases, thereby eliminating porosity; and the apparatus is designed to provide casting which is free of jagged projections in the sprue hole. The aperture in the battery wall is surrounded by a series of plastic annular rings extending outward from the battery wall but being a part thereof. The molten lead surrounds the annular rings and fills the spaces therebetween when it is injected into the cavity.

Abstract: Battery plates are assembled into stacks forming positive and negative rows of lugs and the stacks are placed within the cells in a battery case. Molding channels are automatically formed around the positive and negative rows of lugs and molten lead alloy is automatically introduced into the molding channels to cast the straps and intercell connections simultaneously within the battery case.

Abstract: In the formation of a battery, electrodes are connected to connector bars by mounting the electrodes in cassettes on the side of a horizontal rotatable drum. By rotating the drum, the electrodes travel in a vertically oriented, circular travel path between various work stations. Rotary displacement of the electrodes involves forward and rearward movements. All forward movements are of equal distance. All rearward movements are of equal distance. However, the distances of forward movement are different from those of rearward movement. The work stations include an electrode receiving station, a fluxing station, a connector bar casting station, and an electrode removal station. A conveyor travels horizontally through the cylinder, carrying battery containers to receive the electrodes.

Abstract: A composite mold construction for casting on the connector straps, posts, and terminals for lead acid electrical storage batteries according to the techniques of U.S. Pat. Nos. 3,718,174 and 3,802,488 wherein the mold cavity areas are alternately heated by direct flame on one face and then chilled by a coolant on their opposite face to freeze metal in the cavities without freezing molten metal flowing in adjacent flow channels. A plurality of mold cavity partition inserts are arranged to be interchangeable in the main mold assembly to enable a single mold assembly to be utilized for several arrangements of battery cells, strappings, and terminals. Thermal distortion of the mating parts is minimized to maintain the cavities free of leaks by interfitting under cuts and pinned or otherwise keyed couplings between the relatively thin inserts and the more massive primary portions of the mold assembly.

Abstract: A novel mold having a plurality of channels for casting battery straps and posts on groups of battery positive and negative plates, the mold being equipped with a projection on at least one end of each of the channels, the projections extending into the channels of the mold toward the opposite end of the channel. The lengths of the mold channels are slightly less than the lengths of rows of positive or negative lugs so that the elements of the battery group are gently compressed or squeezed together. The end walls of the mold channels extend beyond the main mold body, a portion of the extended walls being beveled in a direction away from the mold channels.

Abstract: An apparatus for making a battery grid is characterized by a molding die for molding a lead conductor with a plastics frame. The die has runners or channels defining the grid structure, and valves are positioned at the intersections of the channels for the lead conductor and the channels for the plastics frame. The valves are actuable to selectively block the channels for the plastics frame from the channels for the conductor. In the use of the die to form a battery grid, with the valves actuated to block the channels for plastics from the channels for lead, molten lead is injected into the channels therefor and is confined therein to form the conductor. The valves are then actuated to unblock the channels for plastics and hardenable plastics are injected therein to form the plastics frame, with the frame being molded around the conductor at intersections therewith.

Abstract: Apparatus for injecting molten lead from a reservoir into a die mold cavity formed about an aperture in the wall of a plastic battery for casting lead-alloy battery terminal connectors. Batteries are positioned adjacent the molten lead reservoir of the apparatus and mold portions move together to hold the battery containers in a clamp-like action. Molten lead is die cast under pressure into the mold cavity in which a stainless steel threaded nut is positioned. The lead is forced through a heated chamber into a portion of the mold which may be water cooled. The mold is designed to allow venting of gases, thereby eliminating porosity; and the apparatus is designed to provide casting which is free of jagged projections in the sprue hole. The aperture in the battery wall is surrounded by a series of plastic annular rings extending outward from the battery wall but being a part thereof. The molten lead surrounds the annular rings and fills the spaces therebetween when it is injected into the cavity.

Abstract: A plate strap is die-cast integrally with an upstanding conducting member, which may be either a terminal post or a riser to form part of an intercell connector, by means of a mold having a cavity affording an elongated plate strap position which is closed at the top and has slots in the floor through which the plate lugs project, and a chimney position upstanding from the plate strap position to form the upstanding conducting member. The part of the floor between the plate lugs is formed by cylindrical dowels each having a diameter substantially equal to the spacing between adjacent lugs. The dowels are retracted to permit removal of the mold from the plate strap or straps. A single mold may form a row of plate straps associated with a number of intercell connectors and a pair of terminal posts.

Abstract: An automated apparatus for sequentially forming integrally fused battery terminals on a plurality of storage batteries is described wherein a head means having a mold means adjustably mounted thereon is automatically movable with respect to a vertical axis, and has slidably mounted thereon a burning means for automatically producing a variable-intensity flame for melting said battery elements to form said integrally fused battery terminal during a vertial stroke thereof. An automated post burn station is further described having a conveyor means for advancing batteries sequentially to said burning station and for aligning said batteries with respect to said station for the above described fusing process. A plurality of novel sensors incorporated into the automated post burn station facilitates the rapid, automatic processing of batteries, while providing a high degree of safety and reliability.

Abstract: A novel method is provided wherein the grain structure and castability of low antimony lead battery grid alloy is improved by treating that alloy with trace amounts of phosphorus, and more particularly red phosphorus.

Abstract: A novel method is provided wherein the grain structure and castability of low antimony lead battery grid alloy is improved by treating that alloy with trace amounts of phosphorus, and more particularly red phosphorus.

Abstract: Burners are provided above a battery for burning together high profile bushings inserted in the battery cover and lead posts extending generally upward from the battery. The high profile bushings surround the battery posts. In order to insure a complete weld throughout the entire lead bushing and post, the burners are supported in such a way as to orbit between the bushing and post. The burners orbit within this support in close proximity to the heat of the burner flame. To provide heat insulation from the tips of the burner, a heat shield is provided intermediate the battery post and bushings and the rotation mechanism of the burners themselves. Means for automatic ignition of the burners are provided as well as molds for the battery posts and bushings. The molds are provided with a water cooling capability and a separating means which surrounds the molds and holds the battery motionless as the molds are retracted after the burning has taken place.

Abstract: A lead melting furnace or pot, large enough to provide molten metal for 6-18 grid casting machines, is isolated from the casting machines in a separate, remote, room or chamber. The automatically fed, electrically heated, covered and insulated furnace is positioned at a level above the inlet to the casting machines, so that the molten metal is gravity fed from one or more bottom discharge outlets whereby conventional pumps are eliminated and agitation of the molten metal in the furnace minimized. An impedance heated feed line system connects the furnace and casting machines and elevates the molten metal from the relatively low 700.degree.-800.degree. F. temperatures achieved in the furnace to the required 850.degree.-1100.degree. F. casting temperature. A specially designed exhaust hood covers each group (preferably 3) of casting machines to exhaust contaminated gases and simultaneously provide make-up air to minimize the effect on the casting room atmosphere.

Abstract: A method of assembling an electrical battery in which the container is used as part of the jig fixture wherein apertures are formed in the partitions separating the cells of the battery container. The plate groups are placed into each cell and a channel is formed adjacent the plates of like polarity in each plate group such that a part of each plate of like polarity is exposed in its respective channel. Molten metal is caused to flow only in the channels with the battery container in an upright position such that the molten metal flows through the apertures in the partitions to form inter-cell connectors between the respective battery cells and also to join the parts of like polarity in each cell. Compressive pressure is applied to the bus bars on opposing sides of the inter-cell connector to cause an expansion thereof and form a permanent seal where the inter-cell connector passes through each of the apertures in the battery cell partitions.

Abstract: The two half sections of a battery grid mold are provided with means for cooling the portions of the mold sections directly adjacent the grid cavity and for heating the larger rear portions of the mold sections. The means for cooling the mold sections comprise a plurality of coolant passageways disposed forwardly of the vertical mid-plane of each mold section.

Abstract: A novel system for assembling industrial or motive power batteries is described which basically comprises a conveyor surface, a plurality of stacking box means freely movable across said conveyor surface, tilt table means for engaging in tilting said stacking box, and a novel burning apparatus for forming battery straps on any of a plurality of different sized battery stacks formed within said stacking box means. Additionally, a novel automated burning apparatus is provided wherein a plurality of torches are adapted for a square movement across the terminal lugs of the battery stack, thereby facilitating the formation of battery straps and terminal posts on each of a plurality of battery stacks during a single operation. Utilization of the present system facilitates the efficient manufacture of industrial or motive power batteries of any of a number of different sizes.

Abstract: An automated apparatus for sequentially forming integrally fused battery terminals on a plurality of storage batteries is described wherein a head means having a mold means adjustably mounted thereon is automatically movable with respect to a vertical axis, and has slidably mounted thereon a burning means for automatically producing a variable-intensity flame for melting said battery elements to form said integrally fused battery terminal during a vertical stroke thereof. An automated post burn station is further described having a conveyor means for advancing batteries sequentially to said burning station and for aligning said batteries with respect to said station for the above described fusing process. A plurality of novel sensors incorporated into the automated post burn station facilitates the rapid, automatic processing of batteries, while providing a high degree of safety and reliability.

Abstract: In a process for casting a plate grid for a lead-acid storage battery comprising the steps of preparing a casting die assembly including two interengagable die halves between which is formed a casting cavity to cast a plate grid therein and pouring a molten metal of lead or lead alloy into said casting cavity to form said plate grid therein, an air in said casting cavity is vented through gaps between said die halves and then through a narrow air passage in at least one venting member received in either of said die halves so that said venting member is flush with the casting surface of the corresponding die half, said venting member at the top surface having cavity forming portions operatively associated with said die halves.

Abstract: An automated apparatus for sequentially forming integrally fused battery terminals on a plurality of storage batteries is described wherein a head means having a mold means adjustably mounted thereon is automatically movable with respect to a vertical axis, and has slidably mounted thereon a burning means for automatically producing a variable intensity flame for melting said battery elements to form said integrally fused battery terminal during a vertical stroke thereof. A novel molding means is described comprising a structural member composed of aluminum or other high heat transfer material, which is adapted to interchangeably engage an aluminum mold member which mates with a structural housing and which actually forms the voids in which the melting and casting processes take place. The mold members, which are also composed of aluminum or other high heat transfer material, are provided with a novel mold coating consisting essentially of aluminum oxide formed through a hard surface anodizing process.

Abstract: Improved methods and apparatus for positive displacement casting and/or for positive displacement bonding and, more particularly, for automatically forming, on a continuous, reproducible basis, fusion bonds devoid of structural, electrical and cosmetic defects between two or more workpieces by moving a heated electrode into the area to be bonded so as to uniformly heat and melt the portions of the workpieces to be bonded while, at the same time, displacing substantially all of the molten material from the area to be bonded into a storage area or reservoir surrounding the heated electrode where such molten material is maintained in its uniformly heated molten state, and then retracting the electrode so as to permit the molten material to return to the cavity formed by the electrode in the workpieces where such molten material is allowed to cool and solidify, thus forming a flawless bond between the workpieces--thermal or fusion bonds are made in accordance with the methods of the invention and with the apparat

Abstract: The present invention relates to the construction of multi-cell batteries in which bus bars are cast within the battery containers to provide interconnection of groups of plates in each cell. Further the batteries may be provided with inter-cell and terminal connectors integrally cast with the bus bars and removable or permanent tooling is illustrated in suitably adapted form for casting of such bus bars and connectors in one operation.

Abstract: An automated apparatus for sequentially forming integrally fused battery terminals on a plurality of storage batteries is described wherein a head means having a mold means adjustably mounted thereon is automatically movable with respect to a vertical axis, and has slidably mounted thereon a burning means for automatically producing a variable-intensity flame for melting said battery elements to form said integrally fused battery terminal during a vertical stroke thereof. An automated post burn station is further described having a conveyor means for advancing batteries sequentially to said burning station and for aligning said batteries with respect to said station for the above described fusing process. A plurality of novel sensors incorporated into the automated post burn station facilitates the rapid, automatic processing of batteries, while providing a high degree of safety and reliability.

Abstract: Members are welded together by indirect application of heat, as for welding internal battery posts for connecting groups of plates or terminal posts electrically, through the use of a plurality of heated elements simultaneously engaging posts to be welded together, and wherein the configuration of molten material is controlled as the weld cools, by the use of a templet. The elements are heated, preferably by application of open flame through a plurality of mixing systems for the fuel, with one system being provided for each heated element.

Abstract: Methods for positive displacement casting and/or for positive displacement bonding and, more particularly, for automatically locating the bonding apparatus with respect to the workpieces, locking thereon, and, thereafter forming, on a continuous, reproducible basis, fusion bonds devoid of structural, electrical and cosmetic defects between two or more workpieces by moving a heated electrode into the area to be bonded so as to uniformly heat and melt the portions of the workpieces to be bonded while, at the same time, displacing substantially all of the molten material from the area to be bonded into a storage area or reservoir surrounding the heated electrode where such molten material is maintained in its uniformly heated molten state, and then retracting the electrode so as to permit the molten material to return to the cavity formed by the electrode in the workpieces where such molten material is allowed to cool and solidify, thus forming a flawless bond between the workpieces--thermal or fusion bonds are