Abstract: This spot welding method for an aluminum material comprises: a processing step in which, in a plan view, a circular emboss expanded in a direction of superposition on a second aluminum plate side is formed at a position-to-be-welded of a first aluminum plate; an arrangement step in which positions-to-be-welded are superimposed while the expansion side of the emboss faces the second aluminum plate, and the positions-to-be-welded are arranged between a pair of electrodes; a pressing step in which the superimposed aluminum plates are pinched between the electrodes, and a central side excluding a peripheral edge of the emboss is pressed; and an electrification step of performing pressing and electrification. An electrode having a tip diameter larger than the diameter of a root part of the expansion part of the emboss is used.

Abstract: A steam chamber has enhanced planarity of its cooking surface, and a method for making the same via friction welding is provided. An array of stays within the steam chamber are friction welded to the undersurface of the upper plate, opposite the cooking surface, thus minimizing the heat affected zone and distortion of the cooking surface as compared, for example, to arc welding. A lower plate includes an array of holes sized and configured to be engaged by the array of stays, and is then welded to the array of stays via plug welds or rosette welds at the hole/stay junction. The resulting steam chamber preserves a high level of planarity in the cooking surface, while allowing the use of a relatively thin top plate for thermal and cooking efficiency.

Abstract: A second member has a through-portion penetrating toward a first member. An overlapped surface of the second member with the first member includes a recess. The recess is recessed so as to surround an entire periphery of the through-portion. A sealing material is injected into the recess from an injection hole to close a gap between overlapped surfaces of the first member and the second member.

Abstract: An apparatus and method for fastening dissimilar metals like steel and aluminum utilizes a steel rivet and a spot welding machine. The rivet and metals are stacked and the heat from the welder's electric current softens the lower melting point aluminum allowing the rivet to penetrate the aluminum and weld to the steel layer. The fastener may be used to join stacks with several layers of different materials and may be used to apply a threaded socket or stud made from steel or titanium to an aluminum or magnesium alloy structure. Layers of non-conductive materials like plastic and ceramics may also be affixed to a conductive layer using the fastener made from a compatible material that extends through a pilot hole.

Abstract: A method for welding balls provides a component, provides at least two balls, places at least one first ball of the at least two balls on the component, and applies an electrical voltage in such a manner that a current flows through the at least two balls and through the component, wherein the at least two balls are simultaneously welded together and the first ball is simultaneously welded to the component.

Abstract: Vehicle platforms, and systems, subsystems, and components thereof are described. A self-contained vehicle platform or chassis incorporating substantially all of the functional systems, subsystems and components (e.g., mechanical, electrical, structural, etc.) necessary for an operative vehicle. Functional components may include at least energy storage/conversion, propulsion, suspension and wheels, steering, crash protection, and braking systems. Functional components are standardized such that vehicle platforms may be interconnected with a variety of vehicle body designs (also referred to in the art as “top hats”) with minimal or no modification to the functional linkages (e.g., mechanical, structural, electrical, etc.) therebetween. Configurations of functional components are incorporated within the vehicle platform such that there is minimal or no physical overlap between the functional components and the area defined by the vehicle body.

Abstract: A system for increasing joint strength and reducing embrittlement in a resistance spot weld of metal workpieces is disclosed. The system comprises a stackup of first and second metal workpieces, and an interface member disposed between the first and second metal workpieces. The interface member comprises a peripheral wall defining a hollow inner portion. The peripheral wall has a first open end extending to a second open end. The first open end is in contact with the first metal workpiece defining a first weld portion thereon. The second open end is in contact with the second metal workpiece defining a second weld portion thereon. The system further comprises a first electrode configured to contact the first metal workpiece to heat the peripheral wall at the first weld portion and join the first metal workpiece with the first open end of the peripheral wall.

Abstract: An apparatus and method for fastening dissimilar materials like steel, plastic and aluminum. A resistance welding fastener having multiple layers may be used with or without a sealant. The fastener may be used to form an aluminum covered steel laminate via a hemming pattern of attachment. The fastener may have a solid shaft or have an extended reach and have features for interacting with the welding electrode. A variety of electrode tips may be employed to cooperate with the fastener.

Abstract: An apparatus and method for fastening dissimilar materials like steel, plastic and aluminum. A resistance welding fastener having multiple layers may be used with or without a sealant. The fastener may be used to form an aluminum covered steel laminate via a hemming pattern of attachment. The fastener may have a solid shaft or have an extended reach and have features for interacting with the welding electrode. A variety of electrode tips may be employed to cooperate with the fastener.

Abstract: The invention relates to a connecting element (10, 20, 30, 50) for producing a component connection (70) of two components (72, 74; 92) lying against each other by means of the connecting element (10, 20, 30, 50), which is welded to the lower layer (74)—the base layer—by friction, wherein the connecting element (10, 20, 30, 50) has a shaft (18), which has a shaft segment (14) and a head (12) having a flat surface (20) lying on the top side of the head for transmitting the axial force, wherein a drive cutout (22, 32) is introduced into the flat surface (20) in order to transmit a torque.

Abstract: A rotatable connection between a first component and a second component, the rotatable connection comprising: a first connecting piece composed of metal and which is to penetrate the first component over at least the entire thickness of the first component, in which at an end facing the second component, the first connecting piece is welded to the second component.

Abstract: A method is provided for welding in an automated way a sphere onto a metal sheet. The method includes the following steps: providing a sphere; providing a first electrode; picking up the sphere by use of the first electrode; providing a metal sheet; providing a second electrode; pressing the metal sheet and sphere together such that the sphere is pressed against the metal sheet by the first electrode, and the metal sheet is pressed against the sphere by the second electrode; and welding the sphere and the metal sheet together by generating a welding current between the two electrodes.

Abstract: A method of bonding a first panel made of a first material to a second panel made of a second material is provided. The method includes creating a second panel hole in the second panel at a weld location. An insert composed of the first material is inserted into the second panel hole in the second panel. At least a portion of the insert is fittable in the second panel hole and sized to correspond to the second panel hole. The first panel and the insert are welded together at the weld location, thereby bonding the first and second panels. In one embodiment, the first and second panels are placed between the first and second electrodes of a welding gun. A force is applied to clamp the insert and the first panel between the first and second electrodes and a welding current is delivered. A bonded structure is provided.

Abstract: A method of bonding a first panel made of a first material to a second panel made of a second material is provided. The method includes creating a second panel hole in the second panel at a weld location. An insert composed of the first material is inserted into the second panel hole in the second panel. At least a portion of the insert is fittable in the second panel hole and sized to correspond to the second panel hole. The first panel and the insert are welded together at the weld location, thereby bonding the first and second panels. In one embodiment, the first and second panels are placed between the first and second electrodes of a welding gun. A force is applied to clamp the insert and the first panel between the first and second electrodes and a welding current is delivered. A bonded structure is provided.

Abstract: Disclosed is a projection welding method including providing a first metal substrate, a second metal substrate, and a projection material of separate construction from the first metal substrate and the second metal substrate, disposing the metal projection material between the first metal substrate and the second metal substrate, applying a current and pressure to at least one of the first metal substrate and the second metal substrate, melting the metal projection material via the application of the current and pressure, creating a weld between the first metal substrate and the second metal substrate via the melting, and fixedly associating the first metal substrate and the second metal substrate via the weld.

Abstract: A welding material is constructed and arranged to be positioned in electrically conductive relation between exterior surface portions of first and second weldable members at a location where the first and second weldable members are to be joined. The welding material includes at least one welding material member constructed of an electrically conductive metallic welding material capable of melting when heated by application of an electrical current. Each welding material member is mounted on the exterior surface of the first weldable member and then positioned between the exterior surfaces of the first and second weldable members to be electrically conductively disposed therebetween.

Abstract: A welding material assembly is constructed and arranged to position a welding material in electrically conductive relation between exterior surface portions of first and second weldable members at a location where the first and second weldable members are to be joined. The welding material assembly includes at least one welding material member mounted on a flexible carrier sheet in a predetermined arrangement with each welding material member being constructed of an electrically conductive metallic welding material capable of melting when heated by application of an electrical current. Each welding material member is mounted on the sheet such that when the sheet is placed between the exterior surfaces of the first and second weldable members to be welded, each welding material member is electrically conductively disposed therebetween.

Abstract: A welding material in positioned in electrically conductive relation between exterior surface portions of first and second weldable members, such as hydroformed tubes, at a location where the first and second weldable members are to be joined. A welding device comprises first and second electrodes or conductive ends that extend along substantially the entire extent of first sides of the first and second weldable members, respectively. The first and second conductive ends include first and second concave recesses, which nest with the first and second weldable members, respectively. Electrical current is applied across the first and second weldable members by the nesting first and second conductive ends such that the applied current melts the welding material and thereby welds the exterior surface portions to one another. The welding device can be mounted on a robotic mechanism, which can move the welding device between first and second welding positions.

Abstract: A welding material assembly is constructed and arranged to position a welding material in electrically conductive relation between exterior surface portions of first and second weldable members at a location where the first and second weldable members are to be joined. The welding material assembly includes at least one welding material member mounted on a flexible carrier sheet in a predetermined arrangement with each welding material member being constructed of an electrically conductive metallic welding material capable of melting when heated by application of an electrical current. Each welding material member is mounted on the sheet such that when the sheet is placed between the exterior surfaces of the first and second weldable members to be welded, each welding material member is electrically conductively disposed therebetween.

Abstract: A welding material is constructed and arranged to be positioned in electrically conductive relation between exterior surface portions of first and second weldable members at a location where the first and second weldable members are to be joined. The welding material includes at least one welding material member constructed of an electrically conductive metallic welding material capable of melting when heated by application of an electrical current. Each welding material member is mounted on the exterior surface of the first weldable member and then positioned between the exterior surfaces of the first and second weldable members to be electrically conductively disposed therebetween.

Abstract: A method for forming an electrical resistance weld between a metal tube and a metal sheet is disclosed. In the method, a plurality of generally circular protrusions having generally triangular cross sections is formed upon the sheet. Thereafter, electrodes are utilized to flex the tube, while an electrical current is generated for electric resistance welding the sheet to the tube.

Abstract: A welding material in positioned in electrically conductive relation between exterior surface portions of first and second weldable members, such as hydroformed tubes, at a location where the first and second weldable members are to be joined. A welding device comprises first and second electrodes or conductive ends that extend along substantially the entire extent of first sides of the first and second weldable members, respectively. The first and second conductive ends include first and second concave recesses, which nest with the first and second weldable members, respectively. Electrical current is applied across the first and second weldable members by the nesting first and second conductive ends such that the applied current melts the welding material and thereby welds the exterior surface portions to one another. The welding device can be mounted on a robotic mechanism, which can move the welding device between first and second welding positions.

Abstract: Two steel members are resistance welded using a filler therebetween in the form of either an insert or a metallized layer on the inner surface of one steel member. The steel members have respective compositions at least one of which comprises at least one alloying element having a concentration which contributes substantially to solidification cracking extensive enough to produce an unacceptable weld fracture. The filler has a composition which, during welding, melts and mixes with molten metal from the steel members, at the welding location, and dilutes the concentration there of one or more of the alloying elements which contribute substantially to solidification cracking. This reduces substantially the contribution, to solidification cracking, of each alloying element which has been so diluted. The cumulative dilution of these alloying elements is sufficient to produce an acceptable weld fracture.

Abstract: Method of resistance brazing of light metal alloys to form a corrosion resistant structural assembly, comprising: positioning a patch (thickness of about 0.05-0.25 mm and an aspect ratio of about one) of brazing filler metal between and in contact with superimposed light metal (i.e., aluminum, titanium) alloy structural workpieces to define a joining spot, said filler metal consisting of 7-13% silicon, substantial absence of magnesium and copper for aluminum workpieces, and the balance said light metal; while applying high pressure to force the workpieces together at the joining spot to achieve a structural joint, resistively heating the patch to melting without softening the workpieces, except at interfaces with the filler metal, by flowing an electrical current through the patch and aligned portions of the workpieces under ambient conditions and in the absence of flux, the heating and pressure being sufficient to mechanically break up and eliminate any oxides in the workpieces at the joining spot.

Abstract: A method and apparatus for continuously spot-welding galvanized steel sheets overlapped to be bonded by way of a spot welding machine having a pair of electrodes. The galvanized steel sheets clamp a resistance increasing material including a spacer to ensure a gap between the sheets. Bonding surfaces of the galvanized steel sheets partly contact each other when the pair of electrodes pressurize the galvanized steel sheets such that a part of the gap is retained around the spacer between the bonding surfaces. The retained gap has a size in which zinc melted or vapored when a weld current flows between the electrodes can escape through a weld section of the galvanized steel sheets to outside. The method comprises the step of recording an inter-electrode resistance for each spot when the continuous spot welding is executed by the pair of electrodes.

Abstract: The present invention relates to a resistance welding method suitable for use in spot welding between a steel-base metal sheet, which has been plated for rust prevention purposes, and an aluminum-base metal sheet and aims to permit a current to flow at a high density across the plated steel sheet and the aluminum-clad steel sheet, thereby realizing high-quality welding.An aluminum-clad steel sheet comprised of a steel layer having projections and an aluminum layer is interposed between the plated steel sheet and the aluminum-base metal sheet to be welded to each other. An electrode is energized by a predetermined weld current from an alternating power supply. The current path is limited to the area of the projections, and metallic melt formed by melting of the plating is accommodated between the projections, preventing the current-carrying area from being increased.

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 process for producing a PTC device comprising the steps of forming a laminate comprising a PTC composition and at least two electrode plates having the PTC composition sandwiched therebetween, opposing the surface of a lead plate to be electrically connected to each of the electrodes, to the surface of each of the electrode plates of the laminate while contacting at a narrow area, and then passing a current between the electrode and the lead via the narrow contact surface to weld them. By this process, there is obtained a PTC device having, at a portion of the joining interface between each electrode plate and each lead plate, a nugget formed by melting both the plates. This PTC device has a low contact resistance between the PTC composition and the electrode plates.

Abstract: An electric resistance welding method for welding zinc plated steel plates is disclosed. 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 process for producing a PTC device comprising the steps of forming a laminate comprising a PTC composition and at least two electrode plates having the PTC composition sandwiched therebetween, opposing the surface of a lead plate to be electrically connected to each of the electrodes, to the surface of each of the electrode plates of the laminate while contacting at a narrow area, and then passing a current between the electrode and the lead via the narrow contact surface to weld them. By this process, there is obtained a PTC device having, at a portion of the joining interface between each electrode plate and each lead plate, a nugget formed by melting both the plates. This PTC device has a low contact resistance between the PTC composition and the electrode plates.

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 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: A wear member for use between a pair of relatively movable components of a railway vehicle and method of making same are provided and such wear member comprises a metal support adapted to be supported on one of the pair of components and a liner attached to the metal support wherein the liner is made of a polymeric matrix material which is reinforced by a metal structure having openings therein and such metal structure is disposed substantially centrally between opposed surfaces of the polymeric material and the opposed surfaces include a smooth antifriction wear surface engageable by the other of the pair of relatively moveable components; and, the liner is attached in position by metal members extending between the metal structure and the metal support through polymeric material disposed therebetween with a plurality of welds welding the metal members in position between the metal structure and the metal support.

Abstract: In a friction component for brakes, clutches and the like, a core member is adapted for carrying a plurality of friction pads or cups on either or both of its surfaces. According to this invention a cylindrical metal bushing is positioned in an aperture through the core member to contact the bottoms of friction pads on the opposite surfaces of the core. The bushing has annular projections at the ends that make contact with the bottoms of the friction pads and passage of an electrical welding current through the assembly affects welding of the bushing projections to the bottoms of the pads and rigidly secures them to the core member.

Abstract: The invention relates to a method of joining at least two layers of material one of which is made of weldable material. At least one of the layers of material has an opening therein for receiving a ball of weldable material so that the ball rests in contact with the layer of weldable material. The diameter of the hole is in the range of 94% to 96% the diameter of the ball. The diameter of the ball is in the range of 2T to 5T where T is the thickness of the layer of material having the opening therein. Heat and pressure are applied in sufficient amounts and for a sufficient time to weld the ball to the layer of weldable material. The ball is deformed so that it overlaps the other layer in part so as to attach the two layers.

Abstract: A ceramic fiber mat attached to the interior wall or surface of a high temperature chamber of furnace or adapted to overlie an intermediate insulating member positioned between the mat and a furnace wall, the fibers in the mat lying in planes generally perpendicular to the wall, the mat constituting an improved insulation for the wall where the interior of the chamber or furnace will be operating at temperatures in excess of 1600.degree. F.

Abstract: The invention relates to welding of sheet metal covered with non-metallic layers, and relates more particularly to a method for the spot- or roller seam- welding of sheet metal covered with non-metallic layers by removing the layer from the zones to be welded and subsequently applying a rust-protective layer over the welded zones, wherein on the zones to be welded circular or strip-shaped parts of the covering layer are mechanically removed by milling, rasping or grinding; the metallic zones of the sheet metal thus stripped bare are interwelded by means of opposed electrodes; and finally on the welded zones circular or strip-shaped parts, respectively, of a layer are applied by cementing, spraying or painting, for the formation of a uniform covering layer.

Abstract: A method and apparatus for continuously spot-welding galvanized steel sheets overlapped to be bonded by way of a spot welding machine having a pair of electrodes. The galvanized steel sheets clamp a resistance increasing material including a spacer to ensure a gap between the sheets. Bonding surfaces of the galvanized steel sheets partly contact each other when the pair of electrodes pressurize the galvanized steel sheets such that a part of the gap is retained around the spacer between the bonding surfaces. The retained gap has a size in which zinc melted or vapored when a weld current flows between the electrodes can escape through a weld section of the galvanized steel sheets to outside. The method comprises the step of recording an inter-electrode resistance for each spot when the continuous spot welding is executed by the pair of electrodes.