Abstract: The present invention provides a method for manufacturing a lens assembly of a microcolumn having a plurality of microlenses and a plurality of insulating layers alternately interposed between the microlenses. The method includes forming at least one first microlens assembly set (set—1) by anodic-bonding an insulating layer (101) and a microlens (102) together; layering a second microlens assembly set (set—2) on the first microlens assembly set (set—1); and scanning a laser beam, thus welding the first microlens assembly set (set—1) to the microlens of the second microlens assembly set (set—2). The method of the present invention further includes anodic-bonding the microlens assembly sets together.

Abstract: A device including at least one transformer with primer/seconder coil ratio more than one and including a control unit used to control timing and magnetute of the primer current is employed to heat a metal workpiece to be subjected a subsequent forming operation. An homopolar DC generator can also be used as current source for current heating preparing workpiece for forming operation. Subsequent heating, forming and cooling processes of the metal workpiece are carried out in a controlled manner by a central synchronization unit. This process can be applicated in hot metal bulk forging, sheet forming and hot tube blowforming.

Abstract: An apparatus (30) and method for forming of a vehicle's driveshaft (32) is provided which makes use of a PMF process. The coil device used in the PMF apparatus is assembled around the shaft from two or more coil sections (40, 41, 43; 42, 44, 45) firmly attached to one another, and which may be disassembled from one another to allow to remove the formed driveshaft (32).

Abstract: An embodiment of the present invention is a technique to package a device. Heat is localized on a die having bumps on a package substrate using a first induction heater operating at a first frequency. Heat is localized on at least an integrated heat spreader (IHS), a thermal interface material (TIM), an underfill, and a sealant on the die using a second induction heater operating at a second frequency.

Abstract: A liquid phase diffusion bonding method for dissimilar metal sheets by allowing a galvanized steel sheet and an aluminum alloy sheet to come into close contact with each other and pressing both sheets by using a first mold of a liquid phase diffusion bonding apparatus and a second mold of the same; and heating the sheets at approximately the same heat-up rate and at approximately the same temperature to perform liquid phase diffusion bonding of the sheets by using induction heat generated by applying high frequency currents to a first high frequency induction heating coil provided on the first mold and a second high frequency induction heating coil provided on the second mold. The first high frequency induction heating coil and the second high frequency induction heating coil are positioned to sandwich the sheets at predetermined distances from the sheets, respectively.

Abstract: A method for securing components of a vehicular driveshaft includes disposing a neck of an end fitting into the open end of a driveshaft tube. The end fitting is held with respect to the driveshaft tube so that an annular gap is formed between the neck and the driveshaft tube. An inductor is provided about the driveshaft tube adjacent the end receiving the neck. The inductor is energized to generate a magnetic field for collapsing the driveshaft tube about the neck at a high velocity so that the driveshaft tube and the end fitting are welded to each other.

Abstract: A method whereby magnetic and nonmagnetic materials can be joined together firmly and having their joining areas freed from embrittlement and with a minimum of deformation is disclosed. Applied to the process of fitting a ring of nonmagnetic material into an annular space formed between an inner and an outer member each made of magnetic material, the method includes bringing an inner and an outer peripheral surface of the ring of nonmagnetic material each into a semi-molten state and bringing the inner and outer peripheral surfaces of the ring of nonmagnetic material into pressure contact with the inner and outer members, respectively, to join the inner and outer peripheral surfaces to the inner and outer members, respectively, by interfacial fusion.

Abstract: A method for manufacturing a vehicle frame assembly includes the initial steps of providing first and second structural components, disposing portions of the first and second structural components in an overlapping relationship, and generating an electromagnetic field that causes at least one of the overlapping portions of the first and second structural components to move into contact with the other of the overlapping portions of the first and second structural components at a high velocity so as to be joined together to form a joint. Third and fourth structural components are provided. The third and fourth structural components are joined to the first and second structural components together to form a vehicle frame assembly.

Abstract: A steel plate splicing facility includes, a steel plate heating apparatus for retrieving and heating a preceding steel plate and a following steel plate, and a shear-joining apparatus for clamping a tail end portion of the preceding steel plate and a leading end portion of the following steel plate in an overlapping condition by a die and a clamp and shearing them with a punch, such that surfaces of the tail end portion and the leading end portion are newly formed and brought in contact with each other in order to them. The shear-joining apparatus joins the preceding and following steel plates at a temperature equal to or higher than 350° C. and at a percentage clearance c/t equal to or lower than 5%, c/t being defined by c/t=D/(t1+t2)×100 where D represents a distance between the punch and the die, and t1 and t2 represent a thickness of respective steel plates.

Abstract: A hemming machine for joining an inner sheet metal panel with an outer sheet metal panel comprising: a hemming tool containing an electromagnetic coil positioned to electromagnetically crimp and/or weld the outer sheet metal panel to the inner sheet metal panel, where a backing die positioned outside the inner metallic sheet and the outer metallic sheet opposite the electromagnetic coil.

Abstract: A method for securing components of a vehicular driveshaft includes disposing a neck of an end fitting into the open end of a driveshaft tube. The end fitting is held with respect to the driveshaft tube so that an annular gap is formed between the neck and the driveshaft tube. An inductor is provided about the driveshaft tube adjacent the end receiving the neck. The inductor is energized to generate a magnetic field for collapsing the driveshaft tube about the neck at a high velocity so that the driveshaft tube and the end fitting are welded to each other.

Abstract: A method for applying wear resistant material to a substrate, the substrate comprised of material with a substrate coefficient of thermal expansion, the method including applying the wear resistant material to the substrate with application apparatus, the wear resistant material having a wear resistant material coefficient of thermal expansion, the substrate coefficient of thermal expansion within 15% of the wear resistant material coefficient of thermal expansion.

Abstract: An apparatus and a method for forming a localized joint in at least one structural member are provided. The apparatus includes a tool that corresponds to a joint portion of the structural member. An induction coil is disposed in the tool, and a power source is configured to energize the induction coil. A susceptor disposed between the tool and the structural member has a Curie temperature at which the susceptor becomes paramagnetic such that an electromagnetic field induced in the susceptor by the induction coil heats the susceptor to the Curie temperature for forming the joint.

Abstract: There is disclosed herein an apparatus for electromagnetic forming, joining or welding a workpiece, the apparatus including at least two multi-turn solenoid coils wound in a manner that cooperatively encircles the workpiece to be formed. The apparatus also includes an electrically insulative shell encasing each coil and an electromagnetic current source electrically connected to the coils that generates an electromagnetic field. A hinge mechanism connects the insulative shells and a locking mechanism secures the shells and coils around the workpiece during electromagnetic field generation. A conductive rod joins the solenoid coils and permits series current flow between the coils. The apparatus further includes a shaper that encircles the workpiece and which restricts movement of the workpiece during electromagnetic forming. The shaper concentrates the generated electromagnetic field on the workpiece.

Abstract: A method of bonding spacers to an anode plate of a field emission display. An anode plate having separate phosphor regions is provided, wherein a black matrix material is provided to separate the phosphor regions from one another. A magnetic layer is formed on the black matrix material. A thin metal film is formed on the anode plate and the magnetic layer. Spacers are disposed on the metal film above the black matrix material. An electromagnetic induction procedure is performed to heat the magnetic layer and thus serves as a heating source to produce heat, wherein the heat goes through the metal film to heat the spacers. A direct current (D.C.) electric field procedure is performed to bond the spacers to the metal film above the black matrix material.

Abstract: Dry cells are combined in both physical and electrical combination to fabricate a battery. A dry cell strap defined by a solid copper core with a skin or cover of chrome steel bonded to the copper core, is soldered to terminals of adjacent dry cells using induction heat developed by an oscillator/generator operating in the R F frequency range of frequencies. The parts of the dry cell terminal and cell strap which are soldered together are inserted into alignment with the coils of a coil which generates a magnetic field for inducing a heat creating current in the parts aligned with the coils. Virtually immediate temperature elevation throughout the parts in the coil is achieved and soldering is accomplished without applying excess heat to any one part thereof. Heat elevation in the parts to be soldered, is kept to a minimum. The increment of time during which the temperature of the parts is elevated is minimized.

Abstract: A method whereby magnetic and nonmagnetic materials can be joined together firmly and having their joining areas freed from embrittlement and with a minimum of deformation is disclosed. Applied to the process of fitting a ring of nonmagnetic material into an annular space formed between an inner and an outer member each made of magnetic material, the method includes bringing an inner and an outer peripheral surface of the ring of nonmagnetic material each into a semi-molten state and bringing the inner and outer peripheral surfaces of the ring of non-magnetic material into pressure contact with the inner and outer members, respectively, to join the inner and outer peripheral surfaces to the inner and outer members, respectively, by interfacial fusion.

Abstract: A method for joining vehicle components together to form a vehicle frame assembly where the components are formed from dissimilar materials such as metallic and non-metallic materials. A composite body mount bracket may be attached to a structural component of a vehicle body and frame assembly by providing a body mount bracket having an opening formed therethrough and by providing a first structural component formed from a metallic material also having an opening formed therethrough. The body mount bracket is then positioned adjacent the first structural component such that the respective openings are aligned with one another. A second structural component formed of a metallic material is then inserted through the aligned openings. Next, the second structural component is welded first structural component through a magnetic pulse welding technique, and lastly, the second structural component is pulse formed or deformed so as to mechanically clamp the body mount bracket thereto.

Abstract: A multiple head induction sealing system includes at least two ferrite cores mounted which are channel-shaped and arranged so that the open ends of the channels are aligned either perpendicular or parallel to a workflow direction established as the objects to be heated pass beneath the unit. A litz wire coil is disposed proximate to each ferrite core which produces an electromagnetic field within the ferrite core. The ferrite cores and litz wire coil are adapted to direct the electromagnetic field toward an object to heat it.

Abstract: A method for using magnetic fields to heat magnetically susceptible materials within and/or adjacent to adhesives, so as to bond, bind, or fasten solid materials to one another. The system uses alternating magnetic fields that induce eddy currents and generate heat within susceptors. An induction heating tool is used to emit the magnetic field at its work coil, and an electronic controller measures the energy being used by a power converter that generates the alternating current driving the work coil which creates the magnetic field. The heating tool is used in a method of adhesive bonding in which the thickness of the conductive layer of the susceptor is in the range of 0.01-3.0 mils, or the heating event time interval is in the range of 0.05-10.0 seconds, or the average power density of the magnetic field at the susceptor is in the range of 10-5000 Watts per square inch.

Abstract: A method for securing components of a vehicular driveshaft includes disposing a neck of an end fitting into the open end of a driveshaft tube. The end fitting is held with respect to the driveshaft tube so that an annular gap is formed between the neck and the driveshaft tube. An inductor is provided about the driveshaft tube adjacent the end receiving the neck. The inductor is energized to generate a magnetic field for collapsing the driveshaft tube about the neck at a high velocity so that the driveshaft tube and the end fitting are welded to each other.

Abstract: An apparatus and process are provided for bonding of materials by induction heating of an electrically conductive material upon which a second material is bonded. The electrically conductive material is induction heated between a first induction heating plate, and the combination of a frame and a second induction heating plate that is disposed within the frame. The second induction heating plate is removed from the surface of the electrically conductive sheet, while the frame continues to hold the electrically conductive sheet flat, and the second material, in liquid form, is poured into the interior opening of the frame in which the second induction heating plate was originally placed. The liquid material solidifies and bonds to the electrically conductive sheet to produce a bonded product.

Abstract: There is disclosed herein an apparatus for electromagnetic forming, joining or welding a workpiece, the apparatus including at least two multi-turn solenoid coils wound in a manner that cooperatively encircles the workpiece to be formed. The apparatus also includes an electrically insulative shell encasing each coil and an electromagnetic current source electrically connected to the coils that generates an electromagnetic field. A hinge mechanism connects the insulative shells and a locking mechanism secures the shells and coils around the workpiece during electromagnetic field generation. A conductive rod joins the solenoid coils and permits series current flow between the coils. The apparatus further includes a shaper that encircles the workpiece and which restricts movement of the workpiece during electromagnetic forming. The shaper concentrates the generated electromagnetic field on the workpiece.

Abstract: A method and an apparatus produce a connection of at least at one end surface of a carrier matrix of a honeycomb body, in particular a catalyst carrier body, by a joining technique. The matrix is disposed in a tubular jacket and is laminated and/or wound from at least partially structured sheet metal foils or layers. The end surface of the honeycomb body is at least partially heated up with the aid of a surface inductor having induction coils. The induction coils are disposed in such a way that interconnections of the sheet metal foils or layers are established at least at locations, in particular at spots. Such connecting spots are preferably established variably with regard to their extent over the end surface. The surface inductor is variable with regard to the production of connecting locations and/or connecting spots, that is with regard to effective regions.

Abstract: A method and apparatus for inducing a physical change in at least one metal workpiece are provided. Energy is applied to at least a portion of the metal workpiece, the energy being a combination of energies of at least two distinct sources. One of these energies is a pulsed magnetic force (PMF) energy which induces a rapid movement in a portion of the metal workpiece. The second energy is one which acts synergistically with the first energy to impart the desired physical change.

Abstract: A method for securing components of a vehicular driveshaft includes disposing a neck of an end fitting into the open end of a driveshaft tube. The end fitting is held with respect to the driveshaft tube so that an annular gap is formed between the neck and the driveshaft tube. An inductor is provided about the driveshaft tube adjacent the end receiving the neck. The inductor is energized to generate a magnetic field for collapsing the driveshaft tube about the neck at a high velocity so that the driveshaft tube and the end fitting are welded to each other.

Abstract: A through-hole self-piercing rivet 30 is assembled with two metal plates 50 and 52 to retain the plates together as a workpiece 54. When the rivet 30 is to be removed, a pin, such as a contact pin 56, is attached to the rivet by fusion, or a pin, such as a threaded mandrel 78, is attached threadedly to the rivet. The contact pin 56 or the threaded mandrel 78 is withdrawn from the workpiece 54 to thereby withdraw the attached rivet 30 from the workpiece. Devices 62 and 84 provide facility for effecting the attachment of the contact pin 56 and the threaded mandrel 78, respectively, with the rivet 30, and for the extraction of the rivet from the workpiece 54.

Abstract: A method for manufacturing a vehicle frame assembly includes the initial steps of providing first and second structural components, disposing portions of the first and second structural components in an overlapping relationship, and generating an electromagnetic field that causes at least one of the overlapping portions of the first and second structural components to move into contact with the other of the overlapping portions of the first and second structural components at a high velocity so as to be joined together to form a joint. Third and fourth structural components are provided. The third and fourth structural components are joined to the first and second structural components together to form a vehicle frame assembly.

Abstract: An energy storage system for use in a magnetic pulse welding and forming apparatus includes a bank of capacitors and a very-low inductance conductive bus system interconnecting the capacitors. The bus system provides the ability to generate a very high frequency, short duration impulse which is needed for welding. The energy storage system further includes an energy source connected to the capacitors, a discharge device, a charging control device, and a discharge control device for selectively initiating discharge of energy stored in the capacitors. Inductor tools used in connection with the energy storage system are split to allow parts to be welded to be easily mounted into and removed from the inductor tools. One part of the split inductor tool is either rotatable or slidably movable relative to a fixed part of the inductor.

Abstract: A novel apparatus for manufacturing Solid-Solder-Deposit Printed Circuit Boards (SSD-PCBs) by melting solder powder via induction heating consequently forming relatively thick layers of solid solder over the soldering pads of a bare-PCB 230. Solid Solder Deposit (SSD) refers to a relatively thick layer of solid solder metallurgically bonded over the soldering pads of a bare-PCB 230 such as that said SSD-PCB by itself is the source for solder alloy during a subsequent soldering operation. The manufacture of SSD-PCBs provides the electronic assembly industry with ready-to-solder PCBs consequently eliminates the need to use solder paste at the assembly floor. This invention, unlike the prior art for producing SSD-PCBs, utilizes a solder powder pile 232 that is melted by localized electromagnetic induction heating.

Abstract: Reticles and reticle blanks are disclosed, especially for charged-particle-beam microlithography, that include a peripheral frame and a support frame bonded to each other in a manner that substantially reduces distortion at the bonds as well as membrane distortion. The peripheral frame is bonded peripherally to the support frame in any of various manners including an anodic weld of glass and silicon (the glass containing mobile ions) and a eutectic metal silicon bond wherein the metal can be, e.g., gold, aluminum, germanium, or tin. The glass-silicon and eutectic bonds in which the metal is, e.g., gold, are also resistant to chlorine gas used for routine cleaning of the reticle. In the case of the eutectic metal bond, an intervening layer of chrome or nichrome can be applied between the metal layer and the bonding surface to enhance bonding.

Abstract: A method for securing components of a vehicular driveshaft includes disposing a neck of an end fitting into the open end of a driveshaft tube. The end fitting is held with respect to the driveshaft tube so that an annular gap is formed between the neck and the driveshaft tube. An inductor is provided about the driveshaft tube adjacent the end receiving the neck. The inductor is energized to generate a magnetic field for collapsing the driveshaft tube about the neck at a high velocity so that the driveshaft tube and the end fitting are welded to each other.

Abstract: A novel process for manufacturing Solid-Solder-Deposit Printed Circuit Boards (SSD-PCBs) by directly melting dry solder powder over a bare-PCB 230 consequently forming relatively thick individual layers of solid solder over each soldering pad of said bare-PCB 230. Solid Solder Deposit (SSD) refers to a relatively thick layer of solid solder metallurgically bonded over the soldering pads of a bare-PCB 230 such as that said SSD-PCB by itself is the source for solder alloy during a subsequent soldering operation. The manufacture of SSD-PCBs provides the electronic assembly industry with ready-to-solder PCBs consequently eliminates the need to use solder paste at the assembly floor. This invention, unlike the prior art for producing SSD-PCBs, utilizes a dry solder powder pile 232 that is melted by localized heating.

Abstract: A method for securing components of a vehicular driveshaft includes disposing a neck of an end fitting into the open end of a driveshaft tube. The end fitting is held with respect to the driveshaft tube so that an annular gap is formed between the neck and the driveshaft tube. An inductor is provided about the driveshaft tube adjacent the end receiving the neck. The inductor is energized to generate a magnetic field for collapsing the driveshaft tube about the neck at a high velocity so that the driveshaft tube and the end fitting are welded to each other.

Abstract: An energy storage system for use in a magnetic pulse welding and forming apparatus includes a bank of capacitors and a very-low inductance conductive bus system interconnecting the capacitors. The bus system provides the ability to generate a very high frequency, short duration impulse which is needed for welding. The energy storage system further includes an energy source connected to the capacitors, a discharge device, a charging control device, and a discharge control device for selectively initiating discharge of energy stored in the capacitors. Inductor tools used in connection with the energy storage system are split to allow parts to be welded to be easily mounted into and removed from the inductor tools. One part of the split inductor tool is either rotatable or slidably movable relative to a fixed part of the inductor.

Abstract: An apparatus has a single workstation for joining high strength metal components by electromagnetic forming techniques. One of the metal components carries high loads or is subjected to combined stresses and strains, thus requiring that it be relatively strong and ductile. EMF or MPW processes are used to join the components, whose strength is temporarily diminished prior to the joining step. The high strength material is subjected to a retrogressive heating and quenching process along a joined boundary thereof and is then electromagnetically joined. Thereafter, the strength of the diminished material is restored to its higher temper and strength. In a first embodiment, the apparatus uses a single coil for both the heating and electromagnetic bonding of the metal. In a second embodiment, two adjacent coils are used and the material is moved along a work path between the coils.

Abstract: An induction heating coil for joining structural members by heating a bonding material disposed between the structural members includes first and second elements with complementary shapes spaced equidistantly apart along the length of opposing surfaces of the structural members. Bases and risers connected to the first element to a source of high frequency electrical current. Conductive elements connect the first and second elements into a single turn coil. The first and second elements, and at least the riser, are formed of hollow, tubular members to form a coolant flow path therethrough.

Abstract: A method of brazing a plurality of copper strands to a buss bar includes: a) cleaning the buss bar and the copper strands; b) positioning a filler shim on the surface of the buss bar; c) placing a copper strand on the filler shim, the filler shim and the strand having substantially equal lengths; d) stacking additional copper strands on the buss bar, with a filler shim between each adjacent pair of strands; and e) heating the filler shims utilizing an induction brazing coil to a temperature sufficient to cause melting of the shims and to thereby form a brazed lap joint between the copper strands and the buss bar.

Abstract: A static coil induction welding apparatus and method for induction welding thermoplastic composite structures. The apparatus includes a plurality of independent coil segments disposed adjacent one another in side-by-side fashion to form a coil pack. A plurality of such coil packs are disposed in side-by-side fashion to form a coil assembly which covers the entire area of the weld zone. An AC power supply associated with each coil pack applies an AC signal through a switching network to electrically energize its associated coil segments such that the AC signals are in predetermined phase relationships relative to one another, thus generating a plurality of eddy current loops in a susceptor placed between the components being welded. The switching network alternately switches the coil segments such that the AC signals applied to the coil segments are shifted back and forth between adjacently disposed coil segments repeatedly approximately every 0.5 seconds.

Abstract: A bonding method which includes heating an electrically conductive substrate with an induction heating system. The electrically conductive substrate is suitable for receiving a bonding agent which includes a pressure sensitive adhesive or a hot melt adhesive. The bonding agent is attached to a non-conductive substrate. The contact surface of the substrate is heated with the induction heating system to elevate the temperature of the contact surface. The heated surface enhances the wet out of the bonding agent upon application of the bonding agent onto the substrate.

Abstract: The process of bonding a first workpiece to a second workpiece is disclosed comprising the steps of fabricating a sintered bonding pad formed from a matrix of randomly oriented metallic fibers. The bonding pad is interposed between the first and the second workpiece and the first and second workpieces are biased into engagement with the bonding pad. Heat is applied to the first workpiece to the second workpiece for transforming substantially all of the metallic fibers into a liquid for bonding the first workpiece to the second workpiece.

Abstract: According to a method of melting a bump improved to omit processes of flux application, reflow, cleaning and drying, a bump formed on a substrate is heated and melted by electromagnetic induction using an induction heating coil in ambient of low oxygen concentration.

Abstract: A method is disclosed of manufacturing a pulley with integral bearing comprising a sheet metal pulley mounted on the outer race of a bearing. The pulley is a close sliding fit on the outer race. The interstice between the pulley and the race is at least partly filled with a low-melting-point filler metal which, when heated, melts and diffuses by capillary action into the interstice between the pulley and the race, at least partly filling the interstice and fastens the pulley to the race when it solidifies. The filler metal is advantageously a brazing alloy having a melting point much lower than that of the parts to be joined together. Applications of the method include the manufacture of belt tensioning pulleys with integral bearings, as used on automobile vehicle engines, for example.

Abstract: An apparatus and method is provided for conductively bonding at least two conductors together. An inductive coil generates a magnetic field when electrical current is run therethrough. A magnetic concentrator is disposed near the inductive coil and adjacent which the two conductors can be positioned for concentrating the magnetic field on the conductors. The concentrator is independent of the conductors. Pressure is applied to the conductors. The concentrator concentrates the magnetic field generated by the inductive coil on the conductors, thereby heating the conductors under pressure and electrically bonding the conductors together.

Abstract: According to the invention, the rear end of a preceding metal piece and a front end of a succeeding metal piece are heated, pressed and joined prior to the finishing hot rolling. An alternating magnetic field running through the metal pieces in the thickness direction thereof is generated in an end region on opposed faces of the respective metal pieces to perform heating. Another alternating magnetic field whose direction is reverse with respect to that of the former alternating magnetic field is partially generated in the end region on the opposed faces of the metal pieces and in either a region where the metal pieces exist or a region outside width ends of the metal pieces. This assures a uniform heating of the end region on the opposed faces of the metal pieces over their full width to reliably join the both metal pieces to each other.

Abstract: A method and apparatus for joining metal pieces wherein the rear end of a preceding metal piece and a front end of a metal piece are heated and then pressed together prior to hot finished rolling. The temperature the ends of the metal pieces are heated to is a temperature range between the solidus and liquidus line temperatures of the metal(s) to be joined.

Abstract: According to the invention, the rear end of a preceding metal piece and a front end of a succeeding metal piece are heated, pressed and joined prior to the finishing hot rolling. An alternating magnetic field running through the metal pieces in the thickness direction thereof is generated in an end region on opposed faces of the respective metal pieces to perform heating. Another alternating magnetic field whose direction is reverse with respect to that of the former alternating magnetic field is partially generated in the end region on the opposed faces of the metal pieces and in either a region where the metal pieces exist or a region outside width ends of the metal pieces. This assures a uniform heating of the end region on the opposed faces of the metal pieces over their full width to reliably join the both metal pieces to each other.

Abstract: An apparatus and method is provided for conductively bonding at least two conductors together. An inductive coil generates a magnetic field when electrical current is run therethrough. A magnetic concentrator is disposed near the inductive coil and adjacent which the two conductors can be positioned for concentrating the magnetic field on the conductors. The concentrator is independent of the conductors. Pressure is applied to the conductors. The concentrator concentrates the magnetic field generated by the inductive coil on the conductors, thereby heating the conductors under pressure and electrically bonding the conductors together.

Abstract: A method and apparatus for permanently joining two or more metallic vehicle frame components using magnetic impulse welding techniques. The vehicle frame may include a pair of similar or dissimilar tubular side rail members in multiple sections joined together by a plurality of transversely extending tubular or “C” of “U” shaped cross members. A plurality of similar or dissimilar material brackets are joined to the side rails and/or cross members to facilitate the attachment of other portions of the vehicle to the vehicle frame. These components are joined via an overlap joint between two individual side rail sections, a cross member section and a side rail section, or a bracket and a side rail section or a cross member section. The first component and the second component, if tubular side rails, are sized so that they may be disposed telescopically with clearance.

Abstract: Method and apparatus for joining metal pieces using induction heating. Metal pieces to be joined are placed end-to-end with a gap between them and induction heated in the thickness portion. To maximize speed and even heating edge-to-edge of the ends, members of a magnetic substance are provided in a gap between the inductor and the piece to be heated, thereby enhancing local heating effect by increasing magnetic flux density. Once heated, the ends are pressed together end-to-end for joining.