Abstract: The present disclosure provides a battery, a manufacturing method thereof and an electronic product. The battery cell includes electrodes and tabs, where each of the electrodes includes a current collector and an active material layer, and the current collector includes a coating zone coated with the active material layer and an empty foil zone, and an end of a tab overlaps the empty foil zone and the tab and the empty foil zone are connected by laser welding; the side of the empty foil zone facing away from the tab has a plurality of dot-shaped welding marks arranged at intervals, and the dot-shaped welding marks include a concave part and an annular convex part surrounding the concave part. The contact area between the annular convex part and the separator between the positive electrode and the negative electrode is large, and the separator is less likely to be pierced.

Abstract: The present disclosure provides a battery and a portable electrical device. The battery includes a housing and a battery cell disposed in the housing; the battery cell includes electrodes and tabs, where the electrode includes a current collector and an active material layer, and the current collector includes a coating zone coated and an empty foil zone, and an end of the tab is welded to the empty foil zone by a laser welding process; a surface of the empty foil zone facing away from the tab has a plurality of welding zones arranged at intervals, and each welding zone comprises at least one line-shaped welding mark and a surface of the tab facing away from the empty foil zone has no welding mark. The protrusion of the present disclosure is less likely to pierce a separator between a positive electrode and a negative electrode.

Abstract: The invention relates to an electrode (16) for a welding torch (17) or a cutting torch, comprising a main body (1) and a tip (3) arranged on an end surface (2) of the main body (1). The main body (1) is designed as a hollow body that is open on at least one side. On a side opposite one of the tips (3), the main body has an opening (4) for introducing a cooling medium into an interior space (7) of the main body (1), and at least two regions (5, 6) in the interior space (7), the two inner diameters of which are different from one another, and a transition region (8) located between the two regions (5, 6) having an inner diameter that decreases in the direction of the tip (3).

Abstract: A method of joining a multiple member work-piece includes providing a first steel work-piece having a first electrical resistivity and a second steel work-piece having a second electrical resistivity that is lower than the first electrical resistivity. A third material is disposed in contact with the second steel work-piece. The third material has an electrical resistivity that is greater than the second electrical resistivity. The method includes resistance welding the first and second work-pieces together. The third material may be in the form of a rivet, a third work-piece, or a coating material disposed between the first and second work-pieces. A bonded assembly includes steel members and a third material being bonded together, wherein the electrical resistivity of the second member is lower than the electrical resistivity of the first member, and the third material has an electrical resistivity that is greater than the electrical resistivity of the second member.

Abstract: A stacked structure includes a polymer layer and a metal layer. The metal layer is disposed on the polymer layer. A burr length on a surface of the polymer layer is about 0.8 ?m to about 150 ?m, and a burr length on a surface of the metal layer is about 0.8 ?m to about 7 ?m.

Abstract: A system includes a first robotic machine having a first set of capabilities for interacting with a target object; a second robotic machine having a second set of capabilities for interacting with the target object; and a task manager that can determine capability requirements to perform a task on the target object. The task has an associated series of sub-tasks. The task manager can assign a first sequence of sub-tasks for performance by the first robotic machine based on the first set of capabilities and a second sequence of sub-tasks for performance by the second robotic machine based on the second set of capabilities. The first and second robotic machines can coordinate performance of the first sequence of sub-tasks by the first robotic machine with performance of the second sequence of sub-tasks by the second robotic machine to accomplish the task.

Abstract: A control system includes a controller that controls machining of a workpiece, and a photographing device that photographs an image of the workpiece under machining operation. The controller generates a three-dimensional model of the workpiece under machining operation based on the acquired image, compares the generated three-dimensional model and a three-dimensional model generated by a machining simulation with each other, and determines a presence or absence of a machining defect based on a result of the comparison. When the machining defect is present and re-machining is possible, a setting is modified depending on a cause of the machining defect and additional machining is executed based on the modified setting.

Abstract: A welding electrode includes a weld face that has a convex base weld face surface and a plurality of ringed ridges that are radially spaced apart on the base weld face surface and surround a central weld face axis. The plurality of ringed ridges including an innermost ringed ridge and an outermost ringed ridge. The innermost ringed ridge is located closest to the central weld face axis and rises above a central portion of the base weld face surface, and the outermost ringed ridge is located farthest from the central weld face axis and rises above an outer peripheral portion of the base weld face surface. At least one of the plurality of ringed ridges is a discontinuous ringed ridge.

Abstract: The invention relates to a method of welding of at least two metal-based materials (5, 7), non-weldable directly to each other with resistance welding. At least one spacer (6) is joined by welding on at least one of the two surfaces of a material (5) in every interstice between two surfaces of materials to be welded. The welded spacer (6) is utilized so that resistance welding is focused to the surface of the material (5) with the spacer (6) to melt at least one spacer (6) located on the heat affecting zone in order to achieve a weld between the metal-based materials (5, 7).

Abstract: A method for producing a high-pressure fuel pump includes bringing a pump housing into contact with a lower electrode, gripping a pot-shaped cover element using a collet chuck, contacting the cover element with an electrode, bringing the open face of the cover element into contact with the face of the pump housing opposite the lower electrode, centering the cover element on the face of the pump housing opposite the lower electrode, pressing the cover element onto the pump housing in the direction of the lower electrode, and introducing an electrical current from the electrode via the cover element and the pump housing into the lower electrode, such that fusing occurs at the point of contact between the cover element and the pump housing, and such that subsequently the cover element is bonded to the pump housing. The pump housing and the cover element are connected by a peripheral weld seam.

Abstract: Provided is a joint component manufacturing method for reducing occurrence of burrs upon bonding between a first member having a hole and a second member having a shaft portion and firmly bonding both members. In the method for manufacturing a joint component 100, a hole-side weak press-fit portion 112 is formed at a hole 111 of a flat plate ring-shaped first member 110. Moreover, each of a shaft-side weak press-fit portion 122 and a shaft-side strong press-fit portion 124 is formed at a shaft portion 121 of a cylindrical second member 120. The hole-side weak press-fit portion 112 and the shaft-side weak press-fit portion 122 are defined by a first weak press-fit interference Lw1 formed thinner than a first strong press-fit interference Ls1. The shaft-side strong press-fit portion 124 is defined by a first strong press-fit interference Ls1 as the minimum necessary press-fit interference for electric resistance welding upon electric resistance welding between the hole 111 and the shaft portion 121.

Abstract: A method of resistance spot welding a workpiece stack-up comprising overlapping first and second steel workpieces is disclosed, wherein at least one of the steel workpieces comprises an advanced high-strength steel substrate. The workpiece stack-up is positioned between a pair of opposed first and second welding electrodes. A cover is disposed between at least one of the first steel workpiece and the first welding electrode or the second steel workpiece and the second welding electrode at an intended weld site. The workpiece stack-up is clamped between the first and second welding electrodes at the weld site such that at least one of the weld faces of the first and second welding electrodes presses against the cover. The first and second steel workpieces are welded together by passing an electrical current between the first and second welding electrodes at the weld site.

Abstract: A cable protector can include a first side bar welded along a length of a casing section. A second side bar can be welded along the length of the casing section. The second side bar can be positioned substantially parallel to the first side bar. A cable can be positioned between the first side bar and the second side bar. The cable can be positioned while the casing section is being run-in-hole. A cover strip can be welded on top of first side bar and the second side bar. The cover strip can be welded in place while the casing section is being run-in-hole.

Abstract: There is provided a power supply device that supplies an output current to an electric processing device which performs electric processing on workpieces. The device includes: a first power supply; a magnetic energy recovery switch that receives a current supplied from the first power supply, and converts the received current into the output current; and a control unit that controls the magnetic energy recovery switch such that an electric current frequency of the output current includes a first electric current frequency and a second electric current frequency which are different from each other within a one-time electric processing time using the electric processing device.

Abstract: A three-dimensional structure is formed when layers of a material are deposited onto a substrate and scanned with a high energy beam to at least partially melt each layer of the material. Upon scanning the layers at predetermined locations at least a first segment overlapping a second segment and underlapping a third segment is formed.

Abstract: A method of joining together adjacent overlapping copper workpieces by way of resistance spot welding involves providing a workpiece stack-up that includes a first copper workpiece and a second copper workpiece that lies adjacent to the first copper workpiece. The faying surface of the first copper workpiece includes a projection that ascends beyond a surrounding base surface of the faying surface and makes contact, either directly or indirectly, with an opposed faying surface of the second copper workpiece. Once provided, a compressive force is applied against the first and second copper workpieces and an electric current is passed momentarily through the first and second copper workpieces. The electric current initially flows through the projection to generate and concentrate heat within the projection prior to the projection collapsing. This concentrated heat surge allows a metallurgical joint to be established between the first and second copper workpieces.

Abstract: Present disclosure relates to a variable jig which is a jig device to manufacture a battery cell in which an electrode assembly is embedded in a battery case made of a laminate sheet including a resin layer and a metal layer, including a die assembly having an inwardly recessed structure corresponding to a storage configured to mount the electrode assembly located on the laminate sheet or a portion to be molded as the storage; and a fixing die configured to fix an outer periphery of the sheet in a normal position, wherein the die assembly is configured to allow adjustment of at least one of a width or a length of the inward recess according to a size of the electrode assembly.

Abstract: A method of resistance spot welding a workpiece stack-up that includes an aluminum workpiece and an adjacent overlapping steel workpiece is disclosed. The method uses a first welding electrode positioned proximate the aluminum workpiece and a second welding electrode positioned proximate the steel workpiece to effectuate the spot welding process. In an effort to positively affect the strength of the ultimately-formed weld joint, external heat may be supplied to the first welding electrode by an external heating source disposed in heat transfer relation with the first welding electrode either before or after, or both before or after, an electrical current is passed between the first and second welding electrodes to create a molten aluminum weld pool within the aluminum workpiece.

Abstract: A compressor includes a discharge conduit that extends between a discharge valve and a hermetic shell within the hermetic shell. A sealing connection assembly includes a housing mounted to one of the discharge valve and the hermetic shell. An inner surface of the housing has a tapered portion that contracts to a sealing edge. An end portion of the discharge conduit is positioned within the passage of the housing such that an outer surface of the discharge conduit is positioned on and contacts the inner surface of the housing at the sealing edge.

Abstract: A system for spot welding two metal sheets together includes a plurality of conductive particles placed in an interface between the two metal sheets, a first electrode, and a second electrode. The first electrode and the second electrode are arranged to clamp the two metal sheets together such that the conductive particles become embedded into the metal sheets at the interface between the metal sheets. A conductive path is formed from the first electrode to the second electrode through the metal sheets and the plurality of metallic particles.

Abstract: A setting welding device is set forth for setting stud-like auxiliary joining parts in a plurality of layers of material and subjecting them to a mechanical-thermoforming process on a second layer of material and connecting them to said second layer by way of a welding operation. For this purpose, the punch is used to apply to the welding auxiliary joining part mechanical and thermal loads that follow prescribed characteristic force and current curves. Furthermore, a corresponding connecting method that can be realized with the aid of the setting welding device is also disclosed.

Abstract: A method for attaching a metal ring (4) in a bore (3) of a frame (2) made of a different metal, wherein: the ring (4) is set in the bore (3) by way of high-energy forming suitable for urging an outer surface of the ring against the bore (3) with a speed capable of driving out any impurity from an interface between the ring and the frame; the interface between the ring (4) and the frame (2) is heated to a temperature and for a length of time that are determined in accordance with the respective materials of the ring and the frame such as to obtain diffusion welding between the outer surface of the ring and the bore. A single-turn coil for magnetic forming carried out by the method is also described.

Abstract: Methods and process flows for diffusion bonding and forming metallic sheets are disclosed herein. The methods include stacking a first metallic sheet and a second metallic sheet to define a sheet stack. The methods further include creating a pneumatic seal between the first metallic sheet and the second metallic sheet to define a sealed sheet stack that defines a pneumatically isolated region. The methods also include increasing a surface area of the sealed sheet stack to define an expanded sheet stack. The methods further include compressing at least a portion of the expanded sheet stack to form a diffusion bond between a corresponding portion of the first metallic sheet and an opposed portion of the second metallic sheet thereby defining a diffusion bonded sheet stack.

Abstract: Spot welding electrodes with generally dome shaped welding faces are provided with surface features for welding both aluminum alloy sheet assemblies and steel sheet assemblies. A raised circular plateau is formed on the central axis of the dome and, in one embodiment, a suitable number of round bumps are formed in concentric spacing from adjacent the circumference of the plateau toward the circular edge of the welding face. For welding steel workpieces the plateau mainly serves as the engaging feature of the electrode. Both the plateau and concentric bumps are used in penetrating light metal surfaces for suitable current passage. In another embodiment, the domed surface is shaped with concentric terraces for engagement with the workpieces.

Abstract: A friction stir spot welding structure includes a pair configured of an upper side flange portion and a lower side flange portion that are friction stir spot welded together by being pressed by a rotating pin rotating from one thickness direction side at a mutually overlapping location. A pair of protruding portions that project out in a protruding shape from the upper side flange portion toward the lower side flange portion are formed to the upper side flange portion. A pair of engagement holes into which the pair of protruding portions are inserted are formed to the lower side flange portion.

Abstract: The invention relates to rod thermometer device for detecting a temperature, including a plurality of temperature-sensitive elements and a protective sheath having an axis X in which the sensitive elements are partially inserted. The sheath is made of a metal constituting one of the two metals of a thermocouple, and the sensitive elements of a plurality of wires made of a metal other than that of the sheath and constituting the other one of the two metals of a thermocouple, one of the ends of each one of the wires being welded inside the sheath forming a junction for measuring a given thermocouple, the welded ends of the wires being distributed along a plurality of axial and azimuth positions relative to the axis X inside the sheath, each one of the wires extending out of the sheath by at least one of the ends thereof.

Abstract: A method for producing a battery resulting from the joining with a plurality of weld nuggets therebetween of a foil layered part, at which foil exposed portions exposing an aluminum foil overlap, and a positive terminal member made of aluminum, includes: a formation step for forming at the foil layered part a foil welded part at which are formed, by welding aluminum foils together by means of ultrasonic welding, a first high-position part at at least a section of a surface to be joined, and a plurality of first low-position parts distributed at scattered points within the first high-position part; and a resistance-welding step for contacting the first high-position part to the positive terminal member, generating weld nuggets at the first low-position part by flowing an electric current, and resistance-welding the foil welded part and the positive terminal member with the weld nuggets therebetween.

Abstract: A spot welding apparatus may include a fixed welding machine coupled to a fixing frame having a mounting portion mounted on an arm of a robot, a guide plate mounted on the fixing frame, one or more moving welding machines mounted to be selectively and slidingly movable along a longitudinal direction of the guide plate, and an operating unit configured to selectively move the moving welding machine.

Abstract: A battery pack which includes a plurality of contact portions in a terminal accommodating portion provided in each of cell receiving portions of a plurality of battery cells, so that one selected from the plurality of contact portions can be electrically connected to electrode terminals of the battery cells even if the plurality of battery cells have different widths of wide walls. In addition, since the battery pack includes a series/parallel switch provided outside an external pack, a connection method of a plurality of battery cells provided inside the external pack can be switched to series/parallel connection. Further, since the battery pack includes a capacity display unit provided outside an external pack, capacity levels of a plurality of battery cells provided inside the external pack can be identified.

Abstract: A friction stir spot welding structure includes a pair configured of an upper side flange portion and a lower side flange portion that are friction stir spot welded together by being pressed by a rotating pin rotating from one thickness direction side at a mutually overlapping location. A pair of protruding portions that project out in a protruding shape from the upper side flange portion toward the lower side flange portion are formed to the upper side flange portion. A pair of engagement holes into which the pair of protruding portions are inserted are formed to the lower side flange portion.

Abstract: A method of resistance spot welding aluminum alloy workpieces together includes several steps. In one step a welding electrode is provided. The welding electrode has a weld face. In another step, the weld face of the welding electrode is shaped to have a desired radius of curvature. The shaped weld face is then textured to a desired surface roughness, and resistance spot welding using the welding electrode is performed to the aluminum alloy workpieces. In yet another step, the weld face is dressed to an extent sufficient to remove contamination build-up that may have accumulated on the weld face from the aluminum alloy workpieces.

Abstract: A device is provided in which a pressing electrode (19, 105) is advanced toward a steel plate component (48, 131) to press a welding projection (4) of a shaft-shaped component (1) against the steel plate component (48, 131), so that the shaft-shaped component (1) is electric-resistance-welded to the steel plate component (48, 131). Pressing force accumulating means (22, 128) for accumulating the pressing force of the pressing electrode (19, 105) is disposed between a pressing member (17, 106) and a pressed member (18, 121). Detection means (54, 113, 3) activated when the pressing member (17, 106) is located at a predetermined position is provided to apply welding current flowing to the electrode, and pressing force adjusting means (55, 123) for adjusting the activation position of the detection means (54, 113, 3) is provided.

Abstract: A suspension component for a vehicle includes a cast iron body, a high strength steel tube and an adapter ring. The adapter ring includes a protrusion engaged with a face of the cast iron body. The protrusion is heated to a plasticized state as a capacitor is discharged through the protrusion and the face. The adapter ring is welded to the body upon cooling of the adapter ring. The high strength steel tube is fixed to the adapter ring.

Abstract: The invention relates to a welding robot for resistance welding, which exhibits a welding tongs (21), a welding current generator (1) connected to the welding electrodes (24, 25) of the welding tongs (21), for supplying the welding electrodes (24, 25) with electric energy during the resistance welding, and an industrial robot. The industrial robot comprises a robot arm (2) and a robot control device (9) for moving the robot arm (2). The welding tongs (21) is connected to the robot arm (2) and the robot control device (9) is connected to the welding current generator (1) and a tongs drive (26, 27) of the welding tongs (21).

Abstract: In various embodiments, joined sputtering targets are formed at least in part by spray deposition of the sputtering material and/or welding.

Abstract: A semi-automatic welding work cell, including a welding job sequencer that automatically selects a welding schedule for use by an operator in the semi-automatic welding work cell. The automatic selection may be by way of elapsed time, a detection of welding operations, a detection of the amount of welding wire supplied for the welding operation, or a detection of the amount of energy supplied for the welding operation.

Abstract: A turbine component repair apparatus includes: a first die having male and female halves for clamping a first section of a turbine blade with a platform and a root portion of an airfoil, the first die having a recess shaped to receive the root portion and retain a faying surface thereof in predetermined alignment; and a second die having male and female halves for clamping a repair section which defines a tip portion of the airfoil, the second die having a second recess shaped to receive the tip portion and retain a faying surface of the tip portion in predetermined alignment. The first and second dies have mating front faces configured to align their bottom surfaces in a common plane. A alignment device is removably attached to the second die to temporarily align the repair section in the absence of the male half of the second die.

Abstract: Disclosed herein is a rotary jig for battery cells to successively manufacture battery cells having different sizes including a main body configured to have a hexahedral structure having a rotary rod mounted at a lower end thereof, the main body being provided at sides thereof with mounting frames having sizes corresponding to sizes of battery cells so that the battery cells can be uprightly mounted in the mounting frames in a state in which electrode terminals of the battery cells are exposed upward, a die disposed at a lower end of the main body, the die connected to the rotary rod so that the die can be rotated manually or by a rotary motor, and support members formed at the die to support the mounting frames of the main body and the battery cells mounted in the mounting frames, wherein the rotary rod is rotated so that resistance welding is performed with respect to a portion of one of battery cells to be welded using a welding rod located above the battery cell in a state in which the battery cells are m

Abstract: A method for connecting a shaft and a hub, the hub having a first joining portion and a second joining portion for a connection to corresponding joining portions of the shaft. The shaft and the hub are pressed together at contact points in the area of the first joining portions, while the second joining portions are not yet in contact with one another, and a welding current is fed via the contact points of the parts that have been pressed together, so that the contact points fuse. The shaft is pressed into the hub, while the first joining portions are being fused, until substantially a press fit is formed between the second joining portions.

Abstract: A welding assembly including a current generator, a first electrode electrically coupled to the current generator, the first electrode including a first engagement surface, and a second electrode electrically coupled to the current generator, the second electrode including a second engagement surface and defining a recess in the second engagement surface.

Abstract: A method is provided for connecting a diaphragm to a housing of a pressure or force sensor, wherein a measurement element is attached in the housing and can capture a load acting from the outside onto the diaphragm during the use of the finished sensor. A housing ring surface or the housing is situated opposite a diaphragm ring surface of the diaphragm, which are subjected to compressive loading by the load during use of the sensor. A first connection is produced in an inner region between the housing ring surface and the diaphragm ring surface until they rest against each other radially outside the first connection. Then a second connection connects the housing ring surface and the diaphragm ring surface to one another radially outside the first connection up to a shared outer edge. Here, a defined connection depth of the entire double connection is maintained.

Abstract: A heat-curable structural adhesive includes at least one non-rubber-modified epoxy resin; an optional rubber or toughener, one or more epoxy curing agents, one or more epoxy curing catalysts; and a flame retardant mixture that includes (i) alumina trihydrate, (ii) zinc borate and (iii) melamine or a melamine derivative. The structural adhesive is useful for bonding metals to other materials or metals to other metals. The structural adhesive strongly resists ignition when welding is performed in the presence of the uncured material, and does not interfere significantly with weld performance.

Abstract: A method of measuring weld thermal response as a function of time during the production of a resistance weld includes monitoring a first parameter responsive to a change in an electrode mechanical load on workpieces welded together with respect to the electrode mechanical load applied prior to application of the heat, monitoring a second parameter responsive to a change in position of linkage applying the electrode load with respect to linkage position prior to application of the heat, and processing a composite of the first parameter and the second parameter to produce a derived measurement representative of the thermal response of the weld. Electrode force and electrode current are also monitored via sensors and measurements calibrated to provide more accurate information during the welding process.

Abstract: A method for repairing a degraded bolt hole in a casing flange by reaming and removing at least some corrosion on an inside and around the hole to form a reamed hole, mounting the flange to float relative to upper and lower electrodes of a welding machine, radially and axially clamping an area of the flange surrounding the reamed hole, placing upper and lower filler slugs in the reamed hole, placing the electrodes against upper and lower filler slugs and applying a welding current through the electrodes while applying pressure to the filler slugs with the electrodes and resistively heating and melting the filler slugs to form a weldment, and pulsing the welding current on and off. Pulsing may be performed with progressively increasing amounts of current. In situ tempering under the pressure of the electrodes may be performed on a substantially liquid pool formed by the welding current.

Abstract: A method and apparatus inspect a quality of an adhesive material used for joining a pair of work surfaces during a weld-bonding process. A pair of work pieces are at least partially bonded by a layer of the adhesive material, and the dynamic displacement of one or both electrodes is measured through a duration of the resistance welding process to determine relative moisture content of the adhesive. A control action is executed when the dynamic displacement exceeds a stored threshold value. The apparatus includes a welding device having a pair of electrodes for providing a clamping force and an electrical current necessary for forming the welded joint, a sensor for measuring a dynamic displacement of at least one of the pair of electrodes and/or another portion of the welding device during formation of the welded joint. A controller has an algorithm for determining a relative moisture using the dynamic displacement.

Abstract: A vaporizer for an exhaust system of an internal combustion engine has a vaporizer tube and a holding sleeve in which the vaporizer tube is inserted. A clamping sleeve sits on the vaporizer tube. The vaporizer tube includes two circumferentially surrounding clamping surfaces which protrude in a radial direction and cooperate with the holding sleeve and the clamping sleeve such that the clamping surfaces are clamped between the holding sleeve and the clamping sleeve by an axial clamping force to be gastight. At least one of the holding sleeve and the clamping sleeve includes a surrounding sealing edge which rests against the respective clamping surface via a line contact and forms an annular sealing seat. The vaporizer further includes a device preventing relative rotation between the holding sleeve and the vaporizer tube. A heater of the vaporizer is attached to the vaporizer tube using a resistance welding method.

Abstract: A method of fabricating an implantable pulse generator for generating electrical pulses for application to tissue of a patient, the method comprises: providing one or more housing components adapted to house at least pulse generating and switching circuitry of the implantable pulse generator; providing a feedthrough assembly adapted to be coupled with the one or more housing components, the feedthrough assembly comprising an array of feedthrough pins for providing respective electrical connections from a hermetically sealed enclosure formed within the one or more housing components to a location exterior to the enclosure; providing a plurality of welding components with each welding component comprising a first portion adapted to engage a respective feedthrough pin and a second portion for engaging a conductor wire; performing one or more weld operations for each welding component to connect each welding component with a respective feedthrough pin and a respective conductor wire.

Abstract: A method to diagnose weld integrity in a welding process includes monitoring a weld indentation characteristic, comparing the monitored weld indentation characteristic to a threshold weld indentation characteristic, and identifying a discrepant weld when the weld indentation characteristic comparison shows the monitored weld indentation characteristic violates the threshold weld indentation characteristic.

Abstract: A welding electrode includes an electrode holder and an electrode cap removably attached to the holder and having a central longitudinal axis. The cap includes a body having an end, and a welding surface that is substantially smooth and free from any grooves defined therein, and has a first diameter of from about 7 to 10 mm, a first radius of curvature, and a second radius of curvature that is different from the first radius. The cap includes a skirt portion extending away from the body and configured to bear against the holder. The skirt portion has a first face that is substantially parallel to the axis and spaced apart from the surface. The body has a second face interconnecting the first face and the surface, and the body tapers from the first face to the surface. A method of forming a resistance spot weld joint is also disclosed.

Abstract: In spot welding, the condition tolerance for applying a large current in a short time into an aluminum alloy plate or the like is narrow, and also nugget crack sometimes occurs in spot welding. In the case of a mild steel plate, the expulsion sometimes occurs, and thereby a poor weld portion is formed. Due to a pickup removal operation from an electrode tip, the operating ratio is reduced. Here, a PAM control method is employed for raising or dropping a rectified and smoothed voltage EDC output to an inverter circuit, according to a certain set-up ratio in a predetermined time, instead of a conventional PWM control method. By this control method, the nugget can be formed in condition of low heat dissipation and high thermal efficiency. In addition, energy saving and power saving are achieved by using the PAM control method.