Abstract: A welding electrode pair of the present invention has substantially columnar first and second welding electrodes coaxially disposed so that their respective tip end faces face each other. Formed on the tip end face of the first welding electrode is a first contact portion protruding therefrom and extending substantially in parallel thereto across the tip end face. Formed on the tip end face of the second welding electrode are second contact portions protruding therefrom substantially in parallel with the tip end face and the first contact portion as if the second contact portions were fit over the first contact portion, extending across the tip end face, and having a substantially circular arc portion at the projected end thereof.

Abstract: A method and apparatus is provided for welding an edge surface of a curved metal brake shoe to a substantially flat metal brake shoe table surface. The apparatus has a positioning mechanism which positions the brake shoe table in longitudinal alignment with the brake shoe web with one end portion of the table surface abutting the brake shoe web surface over a predetermined distance and with the table surface diverging away from the brake shoe web edge forming a vertex where the surfaces abut. A wheel is provided for pressing the abutting surfaces together at the vertex. Conductors are used to contact both the brake shoe web and the brake shoe table to provide a high frequency alternating potential to the pieces to induce current to flow therebetween and thereby heat the interfacing surfaces in the area of the vertex.

Abstract: The invention relates to a tube with surface-enlarging elements attached to the inside thereof, which elements are in the form of radially inwardly directed pins welded on the tube wall. A method for forming such a tube also is provided, the method comprising inserting a holder for each pin into the tube and moving the holder outwardly to press the pin against the tube wall while welding the pin thereto.

Abstract: A method of producing a brush for a dynamo electric machine comprises the step of passing a heating current through a powder compact of the brush material and a conductive member in electrical contact with said powder compact so as to sinter the compact and connect the conductive member to the compact.

Abstract: A method of manufacturing a solar panel element comprising a metal sheet or sheets secured to fluid-tight tubing substantially continuously along its length by metal which has been heated and cooled, e.g. weld metal, in which the tubing and the metal sheet or sheets are held in contact while they are heated to welding temperature, either forge welding or melting temperature. In the preferred methods, the heating is accomplished by high frequency, electric currents using a proximity conductor. Also, in the preferred methods, the tubing is formed with longitudinal lips as the heating is carried out, and the lips are secured together by welding them together simultaneously with the welding of the sheet or sheets to the tubing.

Abstract: An automotive type internal combustion engine exhaust muffler has a welded butt joint consisting of the ends of a pipe bushing, a lockseam louver tube, and a partition neck into which the tube is pressed, the welded joint preferably being of a structure produced by the magnet arc process.

Abstract: Method and apparatus for manufacturing heat exchanger elements in which metal tubing and metal strip are advanced toward each other to a weld station where they are welded together and the tubing-strip combination are then advanced through a first tube straightener, pulling apparatus, a strip corrugator and second tube straightener. The tubing is also passed through tube straightening and shaping apparatus in advance of the weld point. If the combination is collected after leaving the second straightener, the apparatus which is downstream of the weld point other than the pulling apparatus, is inoperative during the advance of the combination therethrough but the combination is then advanced in the reverse direction through such apparatus which is then operative and cut-off apparatus intermediate the weld point and the first straightener cut the combination into panel element lengths which are transferred to further processing apparatus.

Abstract: A method of repairing a box beam is disclosed in which a cracked or broken portion of a box beam may be repaired and the strength returned to normal by forming a pair of plates that fit snugly about at least one half of the box beam, the plates being welded to the box beam and to each other, each edge of the plates being either welded to its juxtaposed plate or to the box beam to provide full strength to the structure.

Abstract: A method and apparatus is provided for welding an edge surface of a curved metal brake shoe to a substantially flat metal brake shoe table surface. The apparatus has a positioning mechanism which positions the brake shoe table in longitudinal alignment with the brake shoe web with one end portion of the table surface abutting the brake shoe web surface over a predetermined distance and with the table surface diverging away from the brake shoe web edge forming a vertex where the surfaces abut. A wheel is provided for pressing the abutting surfaces together at the vertex. Conductors are used to contact both the brake shoe web and the brake shoe table to provide a high frequency alternating potential to the pieces to induce current to flow therebetween and thereby heat the interfacing surfaces in the area of the vertex.

Abstract: A method and an apparatus for welding an impeller by using TIG process are provided in which one of the blades to be welded to a side plate or shroud plate is disposed so as to form a V-channel with the plate, the V-channel being oriented to face upwardly, and a torch head supported at the tip of a torch rod is placed above a weld line produced by the intersection of the blade and the plate so as to contact the inner surface of the V-channel keeping a proper distance between the tip of the tungsten electrode encased within the torch head and the weld line on which a filler wire of suitable length is disposed.

Abstract: A method is provided for welding an edge surface of a curved metal brake shoe web to a metal brake shoe table. The brake shoe table surface has a greater radius of curvature than the brake shoe web prior to welding. The method consists of the steps of positioning the brake shoe table in longitudinal alignment with the brake shoe web with one end portion of the table surface abutting the brake shoe web surface over a predetermined distance and with the table surface diverging away from the brake shoe web edge to form a vertex where the surfaces abut. The abutting surfaces of the brake shoe web and the brake table are then pressed together at the vertex. The diverging surfaces of the brake shoe web and the brake table are contacted by separate electrodes. The high frequency alternating potential is then provided to each of the electrodes contacting the table and the web to induce a current to flow therebetween and thereby heat the interfacing surfaces in the area of the vertex.

Abstract: A method and apparatus for welding an edge surface of a curved metal brake shoe web to a metal brake shoe table surface. The metal brake shoe table surface has a greater radius of curvature than the brake shoe web edge. The brake shoe table is positioned in longitudinal alignment with the brake shoe web with one end portion of the table surface abutting the brake shoe web surface over a predetermined distance and with the table surface diverging away from the brake shoe web edge surface forming a vertex where the surfaces abut. The abutting surfaces are pressed together at the vertex thereby moving the diverging surface of the brake shoe table into contact with a first conductor which is spaced from the vertex. A positive electrical connection is provided between the brake shoe web and the second conductor.

Abstract: A method for forming a conduit or flow passage extending through and beyond opposite sides of a housing wall. A pair of tubes constituting the external portions of the conduit have radially projecting peripheral flanges formed at their ends. The flanges are placed in face-to-face engagement with flat surfaces on opposite sides of the wall in coaxial alignment with a bore through the wall. The flanges are then pressed against the wall by tubular welding electrodes connected in series in a welding circuit and are simultaneously welded to the wall.

Abstract: A method of providing tubes of the type intended primarily for use in boilers with a variably rifled interior surface. The function of the latter surface is to create turbulence within the tube operative to break up the laminar flow of the water or steam flowing therethrough so as to thereby promote more efficient heat transfer during steam generation and so as to minimize the susceptibility of the tube to overheat due to the effects of nucleate boiling.

Abstract: An improved method for resistance welding two metallic articles, made of dissimilar metals which form brittle intermetallic compounds when melted together. A first one of the metallic articles is provided with a tapered, flat-topped projection which is pressed against the other metallic article. The first article preferably is composed of the metal most difficult to melt, as determined by the four parameters of melting point, electrical resistance, heat conductivity and specific heat.

Abstract: Welding apparatus particularly adapted for use in welding parts into the interior surfaces of a metal tube in a pre-determined pattern obtained by longitudinal and rotational indexing of the tube. An elongated electrode arm, which is selectively flexible in one direction, extends into the tube and has a feed track attached thereto through which the metal pieces to be welded are moved into position to the welding head on the end of the electrode arm. The other end of the electrode arm is rigidly connected to a mount and is electrically insulated therefrom. A hydraulic piston carried by the electrode arm at its free end is actuatable to drive the entire arm sideways in its direction of flexibility so as to bring the piece to be welded into firm contact with the inside of the tube. Electrical current is then passed through the electrode arm and the piece to be welded, to the tube, and then to a grounded contact, to resistance weld the metal piece to the tube.

Abstract: A method of forming a pressure accumulator is disclosed which comprises the steps of advancing a cylindrical resilient metallic sleeve carrying a separator or bladder through the open mouth of a shell forming a part of the casing of the accumulator, the shell including on an inner wall surface thereof an annular groove defining an inwardly directed sharpened lip in the casing wall. The sleeve is positioned such that the outer circumference thereof, adjacent its upper end, is disposed in abutting relation to the said lip. An electrode is placed against the upper end of the sleeve opposite the lip at a position remote from the deformable bladder.

Abstract: A method for manufacturing an electrical connector is disclosed in which the connector itself comprises an aluminum barrel member having a first and a second end, with the barrel member having a recess in its first end adapted to receive an electrical cable and a copper lead member extending axially out of its second end. The method comprises the steps of first forming a second recess in the second end of the barrel member, and forming one end of the copper lead member such that it includes a portion having a reduced cross-sectional area relative to the rest of the copper lead member. This end of the copper lead member is then inserted into the second recess in the barrel member, and electrical current is provided through the copper lead member and the barrel member while simultaneously applying force to bring the end of the copper lead member into engagement with the bottom of the second recess in the barrel member.

Abstract: Method for manufacturing heat exchange panels each comprising a plurality of sub-panels of finite length, each sub-panel comprising a metal tube welded to a metal sheet except at the end portions thereof which are secured to headers in fluid-tight relation thereto, in which method tubing and metal sheet having a length several times the length of the sub-panel are continuously advanced and welded together by high frequency electric current which is interrupted periodically so that a unit several times the length of a sub-panel and having tubing welded to the sheet by a weld which is continuous except at portions of the tubing spaced apart longitudinally by a distance substantially equal to the length of a sub-panel. The unit is cut at the unwelded portions to provide several sub-panels which are assembled to form the heat exchange panels. The metal sheet may be bent during manufacture of the unit to provide sub-panels having stiffening ribs or having projections for interlocking adjacent sub-panels.

Abstract: A wheel nut having wrench flats extending parallel to a central threaded aperture is sheathed by a sheet metal cap which extends down the sides and covers one end of the nut. The end of the cap may extend straight across the end of the nut or may alternatively be domed to surround a volume extending beyond the end. The cap is welded to the nut at either a ring of points or a continuous ring extending around the nut end. Alternatively, the nut may have a radially extending skirt between its ends and the cap may be welded to the laterally extending sides of the skirt. These resistance welded joinders are formed by supporting the cap in loose assembly with the nut in an electrically conductive fixture, bringing a tubular electrode into pressured contact with the uncapped end of the nut and passing an extremely short pulse of high electric current through the contacting surface of the cap and nut end using a capacitive discharge welding circuit.

Abstract: A toroidal ring made from a spiral spring with contiguous turns, such as those used for constituting the inner core of a metal sealing ring. The ring has a weld without filling metal connecting together the two end turns of the spring, this weld being such that continuity of the wire of the spring is provided without altering the contiguous configuration of the turns and the mechanical, physical and chemical properties of the spring are substantially unchanged at this weld. The weld can advantageously be effected by a resistance weld performed with a pulse of electric current.

Abstract: A weldment wherein two members are joined by a weld bounded at a back portion by a back-up member providing improved weld penetration and prevention of undesirable conditions in the weld such as root gaps or blow-throughs. The back-up member may comprise an elongated element secured to the surface of one member and, more specifically, may be welded thereto by a continuous weld.

Abstract: An arcing contact for a high current capacity switch having a pair of switch members in sliding face-to-face engagement is formed from a set of resilient laminations that shunt the switch members as the switch makes on closing or breaks on opening. One end of the set of laminations is mounted on a face of one of the switch members, usually a blade, and the other end of the set of laminations is angled so that the end surfaces or tips bear against a face of the other switch member, usually a termination, when the arcing contact shunts the switch members. While in this position, a deflection of the laminations develops a spring force that urges the tips of the laminations into contact with the termination. The tips are inwardly bevelled with respect to the face of the termination and lie in a common plane so that during electrical connection they are in a substantially parallel relationship with the face of the termination, at substantially the same pressure.

Abstract: Method of joining fuel rod end caps and cladding tubes by resistance pressure welding within a welding chamber. A welding device is brought into engagement with an end portion of a rigidly mounted cladding tube. An opening chuck as well as a divided welding electrode, both of which are mounted at one side of the welding chamber, are shifted along a predetermined length of the cladding tube end portion. The chuck and the divided welding electrode are brought into contact with the cladding tube end portion. Another welding electrode carrying and end cap is thrust into the welding chamber from the other side thereof so that the end cap is fed to the open end of the cladding tube end portion. The welding chamber is sealed by sealing members sealingly engaging the cladding tube end portion and the other welding electrode and then the interior of the welding chamber is evacuated and filled with protective gas. The end cap is pressed onto the open end of the cladding tube end portion.

Abstract: A method of preventing brittle fracture of a pipe structure constructed by welding welded or continuous welded steel pipes, which comprise subjecting a certain length of the seamed portion adjacent to the butt welded portion of the steel pipe to an arc treatment.

Abstract: A technique for forming and mounting a handle which includes the steps of providing a channel-shaped body of metal with opposed flat lugs at its midportion, inserting a metal rod perpendicularly into the channel-shaped body in tangential surface contact with the inside surfaces of the lugs and in abutment with the inside wall surface or web of the body, mounting these interengaging parts horizontally in a holding jig provided adjacent the stationary lower electrode of an electric welder with the bottom lug engaged on the electrode, and lowering the other welding electrode into contact with the upper lug, so as to weld the lugs to the opposite sides of the rod at the tangential contact surfaces.

Abstract: A method and apparatus for positioning nuts to be welded to a base such as a steel sheet. The base is located between a pair of relatively movable welding electrodes, one of which has a retractable nut supporting and locating pin with a tapered shoulder, the pin being movable in the electrode and extending from its contact face. A nut is placed on the pin and locked onto the tapered shoulder. As the electrodes move together to a welding position the supporting and locating pin is depressed so that the nut comes into engagement with the contact face of the respective electrode. The nut is consequently freed from its taper lock on the supporting and locating pin as it is pressed against the base by the contact face of the respective electrode. Welding current is then passed between the electrodes through the nut and the base to weld the nut in place.

Abstract: A welding apparatus for welding together arcuate components, for example a platform and web of a brake shoe comprises a pair of opposed clamping members which are relatively movable to engage the web, one on each side thereof, over a substantial portion of the web surface area. The clamping members are continuously rotated by suitable drive arrangement. Preferably, two such pairs of clamping members are provided for clamping respective webs.

Abstract: A method of and apparatus for fabricating an orificed wall for a feeder for flowing streams of filament forming material such as molten glass by punching an aperture through a plate from one side to the other and then permanently depressing the plate immediately adjacent the aperture at the other side to such an extent that any tendency to bow from the aperture forming operation is essentially negated.

Abstract: A method is disclosed for welding one or more fins or longitudinally extended plate like members to tubes or pipes by means of radio frequency resistance heating. A V-gap necessary for the high frequency welding technique is created by deforming the tube to produce an out of round or ovular shape. The welding is accomplished as the out of round tube or pipe is deformed back to a round shape while at the same time bringing the fin or plate like member into contact with the tube or pipe.

Abstract: Boiler tube studs and a method of welding the studs to boiler tubes are provided. Boiler tubes have a multiplicity of studs welded thereto and extending outwardly therefrom, with refractory material placed over the studs and held thereon to protect the boiler tubes and to prevent deterioration and wear thereof. The studs wear down over a period of time and new studs have to be welded to the tubes periodically. In accordance with the invention, the new studs are welded directly on the worn studs or nubbins without the necessity of grinding down or otherwise removing or partially removing the worn studs. The new studs have recesses in the ends to facilitate being positioned on the old studs in proper welding position and to improve the welding operation.

Abstract: An apparatus is provided for applying gold contacts to a metal member comprising an ultrasonic welding unit, a welding zone for receiving and superposing the foil element and metal member, a stripping plate disposed in the welding zone between the element and the member having an opening therein for superposing and welding the element and member. The gold foil element is welded to the metal member and the stripping plate separates the unwelded portion of the gold foil from the welded portion to leave the welded portion of the gold foil attached to the metal member.

Abstract: An end plug is formed by heat-sealing or welding a V-shaped section cut from the wall of a first pipe to a complementary shaped butt end of a second pipe.

Abstract: A device for connecting a wire to a support, for example a semiconductor device, by means of thermocompression bonding, by buttwelding, has a movable tool for holding the wire while one end is exposed. An electrode is spaced from the wire end and means are provided for producing a high electric voltage between the electrode and the wire end so as to produce a spark discharge therebetween sufficient to melt the wire end and form a ball. The tool is then used to cause thermocompression bonding.

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