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 substrate beneath the galvanized layer.

Abstract: This application relates to a method and apparatus for welding together small oxide coated components by driving a sharp edge or point of one part into a face of another part and then discharging electrical energy, for example, a capacitively stored electrical current through the joint. Precision micrometer control of the distance one part accelerates toward the other along with continuously adjustable spring tension are used to program the inelastic collision of the two parts. The electrical discharge circuit is controlled to provide a controlled arc after collision.

Abstract: Disclosed is a method for welding wear-resisting hard metals directly to iron base members which are slide or wear members of machinery. Hard metals comprising a tungsten carbide and a binder consisting of 15 to 30% by weight of Ni and/or Co is employed as said hard metals. A Ni alloy metal containing no Cr is used as a filler metal.

Abstract: One form of the method includes disposing a silver contact pad on only a portion of a metal body. The joint between the silver contact pad and the metal body includes a metal which is metallurgically compatible with the silver contact pad and with the metal body. Heat and pressure are applied to the joint through welding electrodes. This joins the contact pad to the metal body and forms a metallurgical bond therebetween. In one embodiment, the metal body comprises copper and the compatible metal comprises tin. The welding electrodes may include shaping surfaces thereon so that the contact pad can be joined to the metal body while substantially simultaneously shaping the combination of the contact pad and the metal body. The resultant contact pad is arc-resistant,i.e., resistant to erosion, and has a typical thickness in the range of from about 0.0005" to about 0.010".

Abstract: A process for welding of noble metal foil includes successively piling a noble metal foil and a thin metal sheet having a high electrical resistance on a side of a metal plate having a high corrosion resistance and a high electrical conduction, mutually welding the foil, the sheet and the plate together and dissolving out only the thin metal thin sheet.

Abstract: A method and apparatus for electrostatic bonding of a layered structure having at least one glass stratum by heating the layered structure to a temperature above the annealing point of the glass stratum, by applying a predetermined pressure and voltage potential across the layered structure while the layered structure is maintained at an elevated temperature. Application of pressure across the heated layered structure permits electrostatic bonding of non-complemental surfaces to form a laminated structure.

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: An electric resistance heating element of the hairpin type is provided by a molybdenum disilicide resistance wire loop transversely connected to molybdenum disilicide terminals. The resistance wire is sandwiched between the ends of two pieces of terminal wire and the ends of these pieces are butt welded together on the resistance wire, to form each terminal.

Abstract: In a method of welding a thin titanium tube to a titanium or titanium clad header of a heat exchanger, the titanium tube is inserted into a hole formed through the header and then the body portion of a core is inserted into the hole of the header. The core is provided with a support and a circular flange at a joint between the body portion and the support. The flange is provided with a notch extending radially inwardly of the flange. When the core is inserted into the hole of the header, the flange comes to engage the header and then the front end of an electrode is positioned in the notch to generate an electric arc, while rotating the core or only the flange, between the front end of the electrode and a portion of the header radially separated by a predetermined distance from the titanium tube. Thus, the header and the titanium tube are melted and welded by the arc.

Abstract: The specification discloses a process for manufacture of welded aluminum grating and the like wherein weldable grade aluminum cross bars having a form similar to a wedge having a rounded apex are abutted against bearing bars and a voltage is applied through the parts to create resistance welds. Special preparation such as cleaning or notching of the area of the aluminum bars that are to be welded are eliminated.

Abstract: Copper and aluminum conductors are butt welded or corner welded by a two-part process involving heating and melting the Cu-Al interface with energy from a pulse laser and simultaneously generating a contact pressure. The laser wavelength is 1.06 micrometers or less and a single 8 millisecond pulse is used. Brittle intermetallics are found in the flash but the narrow fusion zone in the weld is substantially free of intermetallics. High conductivity aluminum is successfully welded to electrolytic tough pitch (ETP) copper wire.

Abstract: A leak-tight joint between a Kovar ceramic feed-through and an aluminum housing is obtained by electron beam welding a short length of the outside surface of the Kovar cylindrical shell of the feedthrough to a region of nickel deposited on a thin wall cylindrical tube of aluminum formed in the aluminum housing.

Abstract: A method for producing strong resistance-welded joints between wires and massive workpieces, especially welded joints between nickel-plated copper wires and steel workpieces. The melting of the nickel coating is insured by producing locally high temperatures and pressures, due to the special configuration of the surface of the workpiece. The work surface is provided with bulges or protrusions which cause a concentration of electrical current and electrode pressure.

Abstract: Segments of a rock bit are secured together by electron-beam welding. The segments are slightly spaced apart prior to welding by a thin shim of alloying metal such as titanium which improves ductility of the weld and is a strong carbide-former during welding. The shim is positioned between adjacent segments in the region of the crown or dome of the bit. The resulting welded interface is a fine-grain stress-relieved structure with good ductility and resistance to cracking.

Abstract: An electric resistance furnace adapted for operation at about 1,800.degree. C. or higher temperatures even in an oxidizing or neutral atmosphere is disclosed. The furnace has a cylindrical heating chamber defined by a generally cylindrical heating element made of ceramic material, such as zirconium oxide and lanthanum chromide. The heating element has a wall thickness which is very small at its middle section and gradually increases toward each end. The middle section of the heating element defines the useful part of the heating chamber into which the heat generated by the heating element is effectively concentrated. An electrode comprising an annular foil of platinum is provided at each end of the heating element to pass electric current therethrough.

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: Methods of forming metallic workpieces into ring-shaped components of selected cross-sectional configuration in which roll electrodes both heat the workpiece by electrical resistance and provide the pressure so that the workpiece becomes plastic and flows into the wanted configuration. Apparatus in which the method can be carried out, and tooling for controlling the configuration into which the workpiece is formed.

Abstract: Process for producing a component part of a railway switch or of a railway crossing in which frogs consisting of austenitic manganese steel casting are, with interposition of an intermediate piece, connected by a welding operation with rails consisting of carbon steel, characterized in that an intermediate piece is welded to the portions of the frog or of the component part of the railway crossing which are to be connected with the rails, and in that this intermediate piece consists of austenitic steel, whereupon the frog or the component part of the railway crossing is, together with the intermediate piece, heated to a temperature, preferably to about 1050.degree. C.

Abstract: In combination with a resistance spot welding machine for welding superimposed electrically conductive members an improved apparatus for and method of cleaning welding electrodes and associated portions of the members to be welded are provided utilizing inert gas cooperating with electrical circuitry such that a sequential cleaning of each electrode and its portions are provided which is self starting and ending as a function of the presence of sufficient inert gas.

Abstract: A method of welding aluminum to aluminum by thermal resistance welding, providing good electrical and mechanical characteristics. The method uses special electrodes for thermal heat that are hard and have a high electrical resistance, such as molybdenum or tungsten alloy and also relies on the aluminum oxide coating on the aluminum to provide the desired resistance heating of the aluminum to cause welding of the aluminum material. The machine disclosed provides a means for securing aluminum leads to the start and finish end of an aluminum winding automatically and simultaneously.

Abstract: A process is provided for welding metal bodies together, at least one of the metal bodies comprising a metallic material that is at least 50% glassy. The process comprises (a) clamping overlapped portions of the bodies between electrodes and applying a clamping force to the overlapped portions; (b) passing an electrical current having a rapid decay such that at least about 90% of the energy is delivered in less than about 4 .times. 10.sup.-3 sec through the bodies to melt at least a portion of one of the bodies, and (c) extracting heat from the bodies through the electrodes at a rate of at least about 10.sup.5 .degree. C/sec by employing high conductivity electrodes having a thermal conductivity of at least about 0.30 cal/sec/cm.sup.2 /.degree. C to form a weld nugget joining the bodies. The weld nugget so formed has a shear strength which is at least 25% of the tensile strength of the body having the lowest tensile strength.

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: An improvement in a powder metallurgic manufacturing process where metal powder is compressed and heated in a mould and heat is produced by conducting electric current through the mould and the metal powder as well as through at least one electrically resistive fireproof body in actual contact with the mould where heat produced in the body is transferred to the mould and the metal powder. The improvement comprises maintaining electric tension between 2 and 200 volts; the current efficiency per unit volume of the mould between 20 and 200 W/cm.sup.3 ; and the resistivity of the electrically resistive fireproof body between 0.03 and 100 ohm .times. cm.

Abstract: A battery including a plurality of electrochemically negatively and positively polarized elements interleaved with each other and a plurality of appropriate interelement battery separators, wherein each of the elements has a foil-like metal tab extending therefrom and welded to like tabs from other elements of like polarity and to the battery terminal. The outermost tab of each tab bundle is longer than the other tabs and the free end thereof is folded back against the remainder of the tab and on the outside of the tab bundle for engagement by the welding electrode during welding.

Abstract: The invention is directed to a method of bonding refractory hard metal materials such as TiB.sub.2 wherein aluminum carbide is formed in situ at the interface between the refractory hard metal and a substrate. The bond formation is greatly accelerated by passing an electrical current across the interface.

Abstract: This disclosure relates to the production of an ultimately continuous weld between sheets of heat fusible material using a welding apparatus which includes a supporting frame and at least one assembly of electrodes mounted on the frame and being movable between positions in which the electrodes are biased towards each other and positions in which they are disengaged from each other, the apparatus being characterized in that the electrodes are movable longitudinally in the frame together with material being welded thereby during each welding cycle and the movement of the electrodes between welding cycles is such that each individual weld at least abuts the adjacent welds after passage of the material through the apparatus.

Abstract: A method and apparatus is provided to produce a gold, inlaid contact surface for an electrical contact device by welding gold ribbon segments to the contact device wire base prior to the coining, trimming, slotting and various other forming operations which transform the wire base into a finished contact device. The apparatus features a sequential arrangement of gripping devices which manipulate the gold ribbon for processing as stated above, a welding apparatus for combining the gold ribbon segment with the contact wire base, a cutting device for cutting the gold ribbon and apparatus for forming the finished electrical contact device. The product features a formed contact device including a wire support member and a contact material simultaneously formed and flattened, to provide a minimum amount of inlaid or coined gold for effecting desirable contact characteristics.

Abstract: An electrode system for spot welding difficult-to-weld materials, such as aluminum, wherein a pair of spaced apart electrodes, one of which is a roller, clamp the overlapped strips of material to be spot welded. Mechanism moves the roller electrode toward and away from the other electrode, and other means is operated responsively to this movement for indexing the roller electrode incrementally circumferentially to successively present a new surface to the work held between the electrodes. A control circuit applies DC power to the electrodes such that the roller mentioned has the positive polarity and the other electrode the negative polarity.

Abstract: A method of making a mount for a solid state semi-conductor comprising a mounting part secured to a body element comprising the steps of positioning a mounting part in contact with a body element, applying heat to the body element in the region of the inter-face between the body element and the mounting part by conduction from the mounting part for a time and at a temperature to cause melting of the body element in the region of the inter-face and consequently to cause bonding of the mounting part to the body element.

Abstract: A plurality of conductors forming the armature windings are arranged in a superimposed stack, with their end faces aligned and located over the respective commutator strip or lamella. An electrode presses the stack against the lamella, another electrode, preferably liquid cooled, is applied to the lamella and solder, for example in form of a ribbon, placed against the end faces of the conductors forming the stack. Upon application of current, the solder will melt and flow between the commutator lamella and the conductor strips forming the armature winding to simultaneously, in one step, secure together the conductors and the commutator lamella. The method is particularly applicable to forming the armature windings in d-c motors for example in electric-car driving motors.

Abstract: A method of welding aluminum to aluminum by thermal resistance welding, providing good electrical and mechanical characteristics. The method uses special electrodes for thermal heat that are hard and have a high electrical resistance, such as molybdenum or tungsten alloy and also relies on the aluminum oxide coating on the aluminum to provide the desired resistance heating of the aluminum to cause welding of the aluminum material. The machine disclosed provides a means for securing aluminum leads to the start and finish end of an aluminum winding automatically and simultaneously.

Abstract: In the process of inserting and fastening a thin molybdenum ribbon into the slot of a slotted tungsten rod, for use in the press seal of a high silica glass lamp envelope, a two step welding process is used. The first weld is made with the two welding electrodes at the internal end of the slot. The second weld is made with the electrodes closer to the end of the rod.

Abstract: In a method of making a resistance welding electrode of the type having a copper or copper-base alloy body member and a coating on a surface portion of the body member, the coating defining an outer work-contacting surface of the electrode, and the coating being of a material selected from the group consisting of nickel, berylium, cobalt, iron and high melting point alloys of the foregoing, the improvement wherein the coated surface portion of the body member is shot-peened prior to coating.

Abstract: An electrical tang type terminal for use in fusing aluminum or aluminum alloy wire thereto. The terminal includes an enlargement to absorb part of the active electrode pressure during heat and pressure application, thereby peventing shearing or undue weakening of the softened wire. Prior to fusing, the enlargement is spaced from the opposite portion of the tang or body to which it is to be fused to permit localized heating and some wire deformation. During fusing, the enlargement helps control the mechanical pressure on the softened wire.

Abstract: An electrical resistance element with electrode portions comprising a thin resistance wire of a heat resistant material, such as molybdenum disilicide, MoSi.sub.2, which resistance wire has at least one end electrode of aluminium, having a much greater cross-sectional area than that of the resistance wire, wherein the end portion of the resistance wire is fused into the end portion of the respective electrode portion.Also disclosed is a method of connecting an electrode portion to one end of the resistance wire in an electrical resistance element by placing the end portion of the electrode within a surrounding sleeve, heating the sleeve with the electrode end therein to cause the outermost end portion of the electrode end to form a melt, introducing the resistance wire end into the melt and permitting the melt to solidify and finally removing the electrode and resistance wire connected thereto from the sleeve.

Abstract: A technique for the repair of selenium photoconductor elements is disclosed. The particular method includes applying a concentrated heat source to a damaged area of the photoconductor in an oscillating motion traverse to the damaged area so as to effect a weld of same. The oscillating motion of the heat source enables quick melting and resolidification of a minute area of selenium wihout undesirable recrystallization of the photoconductor.

Abstract: In the production of longitudinally welded pipes, the metal strip is treated with a chemical deoxidizing agent, such as a hydrazine compound, to remove oxides from at least the strip edges, prior to arc welding, to provide an improved weld.

Abstract: Bonds are made between two work pieces by using foils exploded by electrical energy typically stored in a large capacitor. To increase the uniformity of the bond area, a foil having at least one slit cut in the direction of current flow is used. The foil strips separated by the slit are attracted together by the pinch effect when current is applied, tending to eliminate loss of foil through a jetting action during explosion. Platings are made by pressing the foil between the work piece and a plastic layer to which the foil does not adhere. In both bonding and plating, the capacitor is charged with energy sufficient to bring the foil just to its boiling point. This "tuning" is more efficient and minimizes heat and blast effects that might otherwise damage a small work piece.

Abstract: A method of joining a copper contact button to the aluminum headbar of an electrode plate used in the electrolytic industry for the recovery of nonferrous metals. The method consists in the steps of coating the copper contact button with a thin layer of silver, mechanically threading the copper contact button into the aluminum headbar, preheating the assembled copper contact button and aluminum headbar to a temperature ranging from 200.degree. to 900.degree. F, and welding the coated copper contact button to the preheated aluminum headbar. When arc welding, preheating in the temperature range 375.degree. to 475.degree. F prevents oxygen from the copper diffusing into the weld.

Abstract: A method whereby defect-free welds can be produced in joining metallic members of dissimilar materials by electron-beam welding. The method consists in inserting one of the metallic members in openings formed in a metallic plate of the same material as the other metallic member and welding one metallic member to the metallic plate by providing a weld metal, providing by overlay welding on the weld metal a padding metal of a material substantially similar to that of the other metallic member but lower in oxygen content, effecting machining of the outer surface of the padding metal to form a faying surface, and joining by electron beam welding the faying surface of the padding metal to a faying surface formed on the other metallic member whereby the faying surfaces can be rigidly welded.

Abstract: A method for welding dissimilar metals, wherein the end of one of said dissimilar metals is welded to a metal plate by using a filler metal, the material of said metal plate being the same as that of another of said dissimilar metals; and electron beam welding is applied along the interface formed between such a joint surface of said metal plate, which does not include the aforesaid welded portion, and the joint surface of another of said dissimilar metals.

Abstract: In combination with conventional apparatus for joining members of aluminum or other electrically conducting material by resistance welding, adjustable supports for arranging the work-contacting electrodes in spaced proximity to the work, and circuitry for inducing an inert gas shielded arc of alternating current across each electrode and the work, the apparatus being operable to effect self-cleaning of the electrodes as well as the work between successive welding operations.

Abstract: A welding method and means is disclosed utilizing a conductive foil disposed between or adjacent members to be welded together with the foil serving as one electrode and one or both of the members serving as another electrode of the welding circuit and with the members being forced together or with the foil being forced against the members by a separate electrode.

Abstract: Structurally stronger titanium articles are produced by a weld-bonding technique comprising fastening at least two plates of titanium together using spot-welding and curing an adhesive interspersed between the spot-weld nuggets. This weld-bonding may be employed to form lap joints or to stiffen titanium metal plates.

Abstract: A multi-component metal coating consumable is provided in the form of a rod comprised of two different rod portions coaxially butt joined together in end-to-end relationship, one of said rod portions being a composite consisting essentially of at least 10% by weight of coarse particles of a refractory carbide dispersed through an alloy matrix, the other of said rod portions comprising a compatible alloy matrix structure, such that a welding or brazing rod is provided having two working ends, one to augment the other during the application of a hard and wear resistant coating to a metal substrate.

Abstract: A method for welding dissimilar metals, wherein a filler metal is deposited on one end of the aforesaid dissimilar metals to be jointed, said filler metal being of the same material as that of another of said dissimilar metals; the outer surface of the weld metal thus deposited is machined to provide a joint surface adapted for welding; and an electron beam welding is applied along the interface formed between said joint surface of said weld metal thus deposited and the joint surface of another of said dissimilar metals.

Abstract: A method of preparing surfaces of metallic components which are to be adhesive bonded and spot welded is described. The faying surfaces are first prepared for adhesive metal bonding using the most modern effective solutions available for highest strength and corrosion resistance. A primer may be applied upon the faying surfaces for improved corrosion resistance. The surfaces are then abraded in selected areas for spot welding. After spot welding, a bonding adhesive is introduced along one edge of the joint and capillary action assisted by a vacuum draws the adhesive over the entire area of the joint. Alternately, after abrading the selected areas, the adhesive is applied to the faying surfaces, and the spot welding is then accomplished at the abraded areas.

Abstract: Structurally stronger titanium articles are produced by a weld-bonding technique comprising fastening at least two plates of titanium together using spot-welding and applying a bead of adhesive along the edge of the resistance spot-welded joint which, upon heating, flows and fills the separation between the joint components.

Abstract: In a process for fusion-welding a binary combination of an iron alloy containing 50 % by weight or less of nickel and cobalt combined and copper; or a ternary combination of said iron alloy, copper, and iron, including the steps of bringing members of said binary combination or ternary combination into gapless contact with one another and subjecting the contact zone to a treatment including at least one of electron beam welding, laser beam welding, plasma welding, and TIG welding without use of a filler metal, an improvement which is characterized by supplying welding energy necessary to form in the welding zone molten weld metal having such a width and depth that have been determined from the composition and thickness of said base metals so that the composition of the weld metal may fall within the specified area in a diagram, shown in FIG.

Abstract: A method for joining, by molecular diffusion, an element of greater electrical resistance to a surface of substantially lesser electrical resistance. A piece of resistive material capable of being spot welded to the element of greater electrical resistance is placed in contact with both the surface having substantially lesser electrical resistance and the element having the greater electrical resistance. The resistive piece and the resistive element are spot welded to each other, whereby the heat from that spot weld causes the conductive material to be joined to the piece of resistive material by molecular diffusion. The method is particularly useful for joining nichrome wire to copper-clad printed circuit boards and for joining metal fasteners to copper and aluminum sheet metal surfaces.