Abstract: A method for spot welding metal articles having coatings on the surfaces thereof in which the coating on the outer surface of one of the articles is removed by heating the article as a resistance in an electric circuit. This is done using low amperage current. When the coating is removed, the current can flow freely between the electrodes at high current to effect a secure weld without sparking, distortion or boring of the articles.

Abstract: Fusing apparatus and methods for fusing armature wires having an electrically insulating coating to the tangs of a commutator include a pair of spaced apart, side-by-side electrodes. The electrode pair are cojointly brought to bear on a common tang surface overlying an armature wire to be fused. The heat generated during the fusing process vaporizes the insulation on the armature wire to permit the fusing of the wire to the tang under controlled conditions.

Abstract: An arc-melting method is taught for the formation of metallic-second phase composite materials. The method involves the formation of an intermediate composite material comprising a relatively high loading of second phase particles dispersed in a metal matrix. This intermediate material is then combined with an additional amount of metal and arc-melted to form a final composite comprising a lower loading of the second phase particles dispersed in a final metallic matrix. The final metallic matrix may be comprised of a metal, metal alloy, or intermetallic, while the second phase particles may comprise ceramic materials such as borides, carbides, nitrides, silicides, oxides or sulfides.

Abstract: An electric resistance welding method for welding zinc plated steel plates. The zinc plated steel plates having at least one surface covered with a plating layer composed of mainly zinc can be welded by the present invention efficiently while overlapping said plating layers, because a material for increasing the resistance between the zinc plated steel plates is employed in the present invention, and it is either spreaded, coated or bonded on the surface of said plating layers to be joined beforehand. Thus, the electric resistance of zinc plated steel plates can be performed by a lower electric current in a shorter time without deteriorating the anti-corrosion property of zinc plated steel plates, because the electric resistance between the steel plates has been increased by such a material.

Abstract: A method for joining a porous metallic member and a non-porous metallic member includes by passage of an electric current after forming a dense portion on a joining surface of the porous metallic member by caving a projection provided on a joining surface of the non-porous metallic member into said porous metallic member whereby both metallic members are joined firmly without using screws or adhesives.

Abstract: The present invention discloses a weld-through adhesive sealant comprising a heat deformable reactive resin matrix containing randomly oriented, electrically conductive fibers throughout the matrix. In additon, a method of joining two metal members using said adhesive sealand is also disclosed.

Abstract: A full round bushing is formed by laser welding opposed edges of a bimetal member deformed into a generally cylindical configuration. The laser beam parameters are closely controlled so as to limit any adverse affect on a bearing metal layer. The weld only reaches a depth approximately 20% to 75% of a steel reinforcing layer. The beam approaches the seam between opposed edges at an angle of incidence approximately 10.degree. to 45.degree. and at a laser focal point offset 5% to 70% of the spot diameter of the laser beam. An overlap of the pulse spot-welding approximately 50% to 75% is preferable. A machine vision control system is used to locate the seam, moving the bushing to position the seam as desired relative to the laser and to trigger the laser to perform the welding operation.

Abstract: Electrodes used for spot welding of aluminium workpieces are improved by a combination of steps:(a) A roughened surface is formed on the electrode tip, preferably to an average roughness depth of 12 to 30 microns.(b) also an artificial protective coating, e.g. a chromate-based coating or an anodic oxide film, is applied to the workpieces.(c) Optionally the nugget diameter in the initial welding set-up is arranged to be not more than 15% greater than the minimum acceptable.Features (a) and (b) act synergistically to increase the service life of the electrodes, typically to more than 2000 welds.

Abstract: A pressure gauge fabricated from directly welded pieces of dissimilar metals. The gauge includes a casing, a tubular socket, and a Bourdon tube. The casing is fabricated of stainless steel and has an aperture with a flange. The socket is fabricated of aluminum bronze and is positioned within the aperture and flange in line contact therewith. The tubular socket also has a bore. The Bourdon tube is fabricated of stainless steel and is positioned within the bore in line contact therewith. Single weld lines exist along the lines of contact between the casing and the socket and between the socket and the Bourdon tube as caused by welding without a filler or insert material operatively associated with the single weld lines.

Abstract: The invention concerns a method of forming a joint between aluminium workpieces. These carry an artifically applied e.g. chromate or anodic oxide coating on their surface. A curable adhesive containing up to 40% by weight of particulate filler having a maximum particle size of 300 microns is provided between the workpieces to be joined. Resistance welding is performed using a welding electrode whose tip has a surface with an average roughness depth of at least 10 microns. This increases electrode life and makes it possible to use lower welding currents than previously recommended.

Abstract: A compressor comprises a casing having an aperture, a compressor unit provided in the casing, and an electric motor for driving the compressor unit, the electric motor being provided in the casing together with the compressor unit. An iron joint is mounted to the aperture of the casing and is formed with an electrically conductive metal coating having a corrosion resistance greater than that of iron on the surface thereof. The iron joint is comprised of a cylindrical portion and a conical outer surface portion welded to the edge of the aperture by resistance welding. A pipe for sucking or discharging gas to or from the casing is brazed into the cylindrical portion of the iron joint with a copper brazing material.

Abstract: A continuous process for solid-phase edge bonding a plurality of dissimilar metal strips to form a composite edge-bonded strip. A plurality of elongated metal strips of equal thickness are heated and aligned in a substantially planar, edge-to-edge relationship and pass through a pair of compression bonding rollers. The bonding roller form a rectangular-shaped cavity having a width slightly greater than the combined width of the plurality of strips and a height less than that of the strips, to reduce in thickness and further elongate the metal strips without substantially changing the combined width of the strips and to form a solid-phase bond between adjacent side edges of the strips. The strength of the solid-phase bond is substantially equal to that of the parent metal strips such that the composite strip can be cut or stamped to form detail component parts such as electronic lead frames without bond failure.

Abstract: A one piece, welded drum rotor for a gas turbine engine is described. The drum rotor is characterized by disks having a superalloy composition which is different from the seal alloy composition. Several welding techniques are utilized to join the drum rotor components to each other.

Abstract: The quality of a percussion weld is sensed by measuring and analyzing certain features of the weld current signature. Instantaneous current is measured by a Hall sensor and permits isolation of the welder from the monitoring system. Weld quality is strongly correlated to the time to vaporize the nib separating the parts, and the dwell time to forge the parts together after nib explosion. A weld is assumed defective if nib time is too short or dwell time is too long. These quality parameters may be supplemented by weld and forge timing, line voltage, and acoustic information; a weld is rejected if any of these are outside of acceptance limits. Experiments on the percussion welding of silver-cadmium oxide to brass show that cadmium-oxide is decomposed and expelled by the forge pressure and the joint is a silver to brass weld.

Abstract: End portions of first and second metal plates are overlapped with non-cured sealant interposed therebetween. Spot-welding is applied to the overlapped end portions to assure tight joining between the first and second metal plates. The joined metal plates are then coated with paint and put in an oven for not only drying the paint but also melting the sealant. During this drying process, the melted sealant flows into an entire clearance defined between the overlapped end portions of the first and second metal plates. The joined first and second metal plates are then cooled to solidify the sealant.

Abstract: The disclosure relates to a method whereby complex shapes, not moldable in a single molding operation, are molded in plural parts, each part being of the same or different powdered metal composition or prealloy of the type disclosed. One or more of the parts preferably has bumps or dimples thereon for joining to another of the parts in the manner to be described. The other part can also have depressions for receiving the bumps to aid in alignment of the parts prior to processing.

Abstract: An arrangement for bimetallic contacts, especially bimetallic welded contacts, in which wires of metals having different conductivity, e.g. silver and iron, are butt-welded with one another by electrical resistance welding without noticeable deformation of the connecting point. The wires are then sheared off at both sides of the connecting point. The bimetallic pins are formed by cold-pressing to the final bimetallic contacts whose head cross-sections are larger than the possibly different cross-sections of the wires for the manufacture.

Abstract: The invention is a weld metal for welding of a titanium alloy member to a ferrous based alloy member as an intermediate transition zone between such members so as to overcome the metallurgical imcompatability of each such member, and which consists of a vanadium metal, titanium and iron and inconsequential amounts of brittle intermetallic compounds. The preferred weld metal is vanadium rich and contains no more than 50% combined weight of titanium and such a weld metal is produced in accordance with our invention by fusion welding, particularly capacitor discharge welding, which because of its inherent but heretofore unrecognized extremely fast quench or freeze rates will produce a fusion weld between these two metallurgically incompatible alloys which is free of brittle intermetallic compounds. It is also part of our invention that such a weld metal of the aforesaid composition will have independent use as a welding alloy, particularly when fabricated in sheet form.

Abstract: A method for laser-light welding of a metallic base layer to a thin, metallic covering lying thereon, whereby the covering which is highly reflective for the laser light is covered with a metal skin which is less highly reflective for the laser light, namely with a metal skin which noticeably absorbs the laser light. In case both the covering as well as the base layer are wettable with solder metal, the covering highly reflective for the laser light is first covered with a metal skin composed of a solder metal, whereupon said covering is welded to the base layer by means of the laser light.

Abstract: A method for welding a wound core constituted by an amorphous ribbon which comprises the steps of bringing a pair of electrodes into contact with the surface of the outer end portion of the ribbon, and supplying an electric pulse to the pair of electrodes to instantaneously melt the above outer end portion and the underlying ribbon layer thereby welding them together without causing deterioration in the magnetic characteristics thereof.

Abstract: A weldable sealant composition is made by adding ferrous metal particles to a sealant having a viscosity of at least 6 million centipoises. The sealant composition is placed between two metal plates and permits resistance welding, i.e. spot welding, to take place.

Abstract: A method of resistance-welding two laminates each having a basic structure of a metal layer/a thermally softenable insulating layer/a metal layer, which allows welding with excellent welding strength and good outer appearance of a welded spot. In this method, two laminates are prepared in which each metal layer has a thickness of 0.02 to 0.5 mm, and a ratio of the total thickness of the metal layers of each laminate to the thickness of the laminate falls within a range between 1/3 and 2/3. Electrodes held at a temperature above the softening temperature of the insulating layers are urged against the laminates to soften the insulating layers and so bring the metal layers into contact with each other and to resistance-weld the laminates.

Abstract: A resistance welding method, including the steps of contacting electrodes to two parts to be welded together, faying the two parts at a location to be welded, and passing electrical current between the electrodes and through said location, wherein the improvement comprises, on the parts, a roughened surface means for decreasing heat generation where an electrode makes contact and a uniform coating means at the faying location, the coating means performing the function of generating heat to form a nugget without expulsion.

Abstract: A tool for warm and hot forgings is proposed which is made by bonding cemented carbide to steel by applying electron beams or laser to the joint. The cemented carbide includes a hard phase of tungsten carbide and a binder metal phase containing at least one of Ni, Co and Fe, and at least one of Cr, Mo and W, the latter forming a solid solution. A process for manufacturing such a tool is also proposed in which unfocussed high-energy beams are applied to each side of the joint and focussed beams are then applied to a point slightly away from the joint toward the cemented carbide.

Abstract: Spot- and projection-welding of aluminum sheets has always been connected with difficulties mainly because of the surface layers of aluminum oxide, and even by pickling, these difficulties could be only partly eliminated. The main difficulties have always been insufficient electrode life times, the unsatisfactory quality of the weld and especially the unsolved problem of achieving good quality welding and long electrode-life when using un-pretreated aluminum sheets. The problem has been solved in principle by using electrodes having profiled contact-surfaces, by means of which the layer of oxide is broken during pre-pressing and a direct contact between the electrode and unoxidized material of the workpiece is provided, the contact-resistance of which is lower than the portion of the overall resistance of the point of weld formed by the metal of the aluminum sheets to be welded together.

Abstract: In a vacuum tube with a window through which radiation is passed, an entrance window member is formed of radiation transparent metal, such as titanium or a titanium-base alloy. An entrance window supporting frame, which defines the window, is formed of iron or an alloy containing iron. The flat inner surface of the entrance window member is tacked to the flat outer surface of the entrance window supporting frame along the whole perimeter thereof by tack welding. An intermediate member formed of a metal containing gold or silver is interposed between the respective peripheral edge portions of the entrance window member and the entrance window supporting frame, whereby the entrance window member is finally welded to the peripheral edge portion of the entrance window supporting frame along the whole perimeter thereof in a vacuum-tight manner by continuous spot welding. The position for the final welding is at a predetermined distance from the weld zone of the tack welding.

Abstract: A coating in the form of a silver-based foil or strip is fixed onto a protuberance of a contact finger by resistance brazing while applying a force to crush the protuberance which constitutes the foundation of the strip.

Abstract: An improved resistance welding electrode cap adapted to being internally cooled with a flow of coolant has a main body portion with a nose root at one end and an electrical and coolant connection projecting from the other, the area of the root being substantially smaller than that of the direct projection of the main body portion, a pronounced nose projecting from the root. The whole nose is of dispersion-strengthened copper, as is at least the main body portion. Such cap provides astonishingly improved performance for resistance welding, even of galvanized steel, and particularly of double-sided, galvanized cold-rolled steel sheet.

Abstract: This invention provides a method of electric current welding in a flowing inert gas atmosphere of an electric feedthrough assembly for an electric lamp, and an apparatus for performing such welds. The method and apparatus are well suited to welding refractory metals, e.g., a molybdenum-titanium-nickel alloy feedthrough body a tungsten electrode for use in an alumina arc tube of a high-pressure sodium lamp, and a molybdenum lead-in wire pin. When the tungsten electrode is inserted into a receiving cavity in the feedthrough body and appropriate pressure applied, the electrical resistance of the solid-to-solid rough interface is greater than that of either the electrode pin or feedthrough so that application of an appropriate electrical pulse causes melting to occur only in the immediate vicinity of the interface whereby extensive recrystallization of the feedthrough body does not occur.

Abstract: For making defect-free welds for joining two austenitic stainless steel mers, using gas tungsten-arc welding, a thin foil-like iron member is placed between the two steel members to be joined, prior to making the weld, with the foil-like iron member having a higher melting point than the stainless steel members. When the weld is formed, there results a weld nugget comprising melted and then solidified portions of the joined members with small portions of the foil-like iron member projecting into the solidified weld nugget. The portions of the weld nugget proximate the small portions of the foil-like iron member which project into the weld nugget are relatively rich in iron. This causes these iron-rich nugget portions to display substantial delta ferrite during solidification of the weld nugget which eliminates weld defects which could otherwise occur.

Abstract: A process is described for preparing aluminum sheet for resistance welding, which increases the useful life of the welding electrodes used for welding the thus prepared sheet. The process comprises the steps of: (a) treating both surfaces of the sheet portion to be welded to remove the non-uniform mill finish oxide layer and provide clean surfaces, and (b) providing a thin oxide layer on one cleaned surface and a thicker oxide layer on the other cleaned surface of said sheet, thereby creating a differential in oxide thickness between the surfaces of the sheet and hence a differential in surface resistance.

Abstract: A method for preventing discoloration of the area around an indentation in spot welding is provided in which the weld zone and its surrounding area are masked with a non-oxidizing gas such as argon gas, helium gas, nitrogen gas or a mixture of argon gas and carbon dioxide gas from ambient atmospheric air and spot welding is carried out in the atmosphere of the non-oxidizing gas to prevent the discoloration from occurring at the weld zone of a metal sheet under the influence of heat during spot welding.

Abstract: A method of welding two HY-steel members to produce a weld joint having improved impact toughness. The surface to be welded are first machined, roto-blasted and cleaned with acetone. Then, an insert of Inconel 600 is provided and cleaned with acetone. Next, the Inconel 600 insert is introduced between the surfaces to be welded and the HY-steel members are butted against the insert. Then, a laser welding beam is applied to the Inconel 600 insert to weld together the assembly of steel members and insert.

Abstract: A method of joining a plurality of electrically conductive members is disclosed which comprises the steps of placing the metal members in stack between a pair of electrodes, heating the members to a predetermined temperature range by feeding an electric current through the members while applying a predetermined pressure to the members and cooling the members quickly.

Abstract: A method of welding electrical contacts onto conductive bodies including engaging a surface of the contact with the conductive body and passing a welding current through a pair of spaced surface areas of the contact to provide weld action and wherein a rib portion between the pair of spaced areas retains unoxidized metal thereon to improve electrical contact properties of any article made and utilizing the contact and particularly the ribbed area thereof for make and break engagement with other members of an electric circuit.A new control article is also provided wherein a contact therein has a raised center rib thereon for contacting an associated means for make and break circuit action, which contact is made from silver or silver alloy and has uncontaminated silver on the surface of the rib or center area of the contact.

Abstract: A gas-tungsten arc welding method for joining together structures formed of aluminum alloy with these structures disposed contiguously to a heat-damagable substrate of a metal dissimilar to the aluminum alloy. The method of the present invention is practiced by diamond machining the fay surfaces of the aluminum alloy structures to provide a mirror finish thereon having a surface roughness in the order of about one microinch. The fay surfaces are aligned and heated sufficiently by the tungsten electrode to fuse the aluminum alloy contiguous to the fay surfaces to effect the weld joint. The heat input used to provide an oxide-free weld is significantly less than that required if the fay surfaces were prepared by using conventional chemical and mechanical practices.

Abstract: A method for resistance welding zinc-coated steel members is described wherein at least one member comprises a copper layer intermediate the steel and the zinc coating. The copper layer melts during welding and seals fissures within the fused steel to produce a hermetic weld. The copper layer also protects exterior surfaces where the zinc coating is disrupted by the welding operation.

Abstract: A vacuum vessel, used for such as an X-ray image intensifier, is provided with a radiation-permeable window member prepared from titanium or alloys thereof. The window member is supported on a support frame of iron or alloys thereof by resistance welding. A method of manufacturing the vacuum vessel comprises the steps of: successively spot welding the periphery of the window member by resistive heating to a support frame made of iron or alloys thereof with a pressure of 40-200 kg/cm.sup.2 while interposing a metal foil insert member having a lower melting point than the transformation point of the window member between the window member and the support frame; and hermetically sealing the periphery of the window member in the support frame.

Abstract: A joint structure of a watch body and a bezel comprising a watch body with a joint surface, a bezel with a joint surface, at least one projection extending from one of the joint surfaces welded onto the other surface, a space between said surfaces and connecting material filling said space. By thus constructing, the watch body and bezel have a durable water and air tight joint.

Abstract: Disclosed is a process for the preparation of welded cans, which comprises forming a blank into a cylinder and passing a lap portion of the formed cylinder between a pair of electrode rollers through an electrode wire to effect electric resistance welding, wherein said blank is a tin-free steel blank comprising a steel plate substrate, a layer of metallic chromium formed on the surface of the steel plate substrate and a layer of chromium oxide formed on the metallic chromium layer, and electric resistance welding is carried out in an inert atmosphere in the state where an electrode wire having a plated layer of a soft metal selected from the group consisting of tin and alloys thereof, the thickness of said plated layer being 0.1 to 20 .mu.m, is kept in close contact with the chromium oxide layer of the tin-free steel blank.

Abstract: A method for detecting whether dissimilar metals or alloys are being welded together is disclosed. Metals or alloys are welded together and electrical leads connected to a multi-purpose potentiometer or a voltmeter contact each metal at points heat conductively remote from the weld. The arrangement performs as a thermocouple with the weld acting as the "hot junction" and the contact points remote from the weld being at substantially ambient temperature, and acting as the "cold junction." According to the thermoelectric laws, if the metals are dissimilar, a current and EMF result provided that the hot junction and the cold junction are at different temperatures. If the metals are similar, no signal is generated. The potentiometer or the voltmeter detects whether any electrical signal is present. In the same manner, an unknown metal may be positively identified by welding it to different reference metals until no signal is generated.

Abstract: A method of forming thin steel plate of predetermined dimensions into a tubular form such as a cylindrical or square tubular form and subjecting the side seam or the overlapped portion of the form to electric resistance seam welding by passing it between upper and lower electrodes, which comprises applying a higher welding current to both edge parts of the overlapped portion than to the other parts or the center of the overlapped portion thereby adjusting a welding current to such a value which does not substantially cause the formation of burrs but provides the center with a desired weld strength.

Abstract: The present invention is directed to an improved method and apparatus for effecting spot welds between superimposed sheets of galvanized metal. In accordance with the method, one of the electrodes is comprised of a consumable tip component, preferably a steel ball, whereby predictable and repeatable welding conditions are effected at each welding cycle. The invention is further directed to a method of effecting spot welds between galvanized sheets which includes the step of interposing between a conductive carrier electrode and the metal surface a consumable metallic increment having reduced contact area adapted to engage the galvanized sheet, the consumable component being compatible with the ferrous subtrate beneath the galvanized layer.

Abstract: The invention relates to a method for making a thin walled diaphragm unit of the type used in pressostats and thermostats. The method involves attaching a ring element to one end of a tubularly shaped diaphragm element which may have the bellows forming corrugations formed thereon either before or after the attachment of the ring element. Electrodes are utilized for physically pressing the parts together as well as providing for a flow of current through the joint to provide a metallurgical joining of the parts. A layer of an alloy of phosphorous and nickel is applied to the ring element which results in a heat joining of the parts which in effect is between soldering and welding.

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: After measuring the bulk resistance the surface of high strength low alloy steel material is treated to form a high resistance coating on its surface. When resistance welding the material the coating permits weld formation without significant expulsion or excessive electrode force over a wide range of operating conditions.

Abstract: Process for joining by electron beam bombardment a copper member to a member made from a refractory metal, wherein a layer of metal chosen from among the group containing chrome and nickel is deposited on the copper member in the area where the electron beam brings about its fusion.The members joined by the process of the invention can in particular be used under ultravacuum conditions and in electric power applications.

Abstract: A method of joining two metal members to a graphite member to form a structure having a low transition resistance is described. The method includes the steps of providing a plurality of openings in the graphite member, interposing the graphite member between the two metal members and positioning the metal members to cover the openings in the graphite member, and resistance spot welding the metal members to the graphite member at the openings in the graphite member. This method is advantageous in forming a bus-bar connection between a pair of opposite polarity graphite electrodes in an electrochemical cell stack, such as a zinc-chloride battery. In this particular application, it is preferred that titanium be used for the metal members.

Abstract: Disclosed are a method of and apparatus for making a welded metallic can body by effecting a mash resistance welding on a lapped side portion of a can body preform by means of a combination of a cooled elongated electrode and a cooled rotary electrode and, as required, with wire electrodes interposed between the lapped side portion and these electrodes. Also, disclosed are a tinfree steel welded can body and its making method wherein it is formed by a mash resistance welding on a lapped side portion of a can body preform made from tinfree steel, without requiring the removal of surface chromium film from the welded portion and its vicinity.

Abstract: Disclosed are a method of and apparatus for making a welded metallic can body by effecting a mash resistance welding on a lapped side portion of a can body preform by means of a combination of a cooled elongated electrode and a cooled rotary electrode and, as required, with wire electrodes interposed between the lapped side portion and these electrodes. Also, disclosed are a tinfree steel welded can body and its making method wherein it is formed by a mash resistance welding on a lapped side portion of a can body preform made from tinfree steel, without requiring the removal of surface chromium film from the welded portion and its vicinity.