Abstract: A method for producing metallic honeycomb bodies contains the step of stacking and/or winding of at least partially structured metallic foils to form a honeycomb structure with channels. The metallic foils are heated using at least one radiant heater from the open front face of the channels, whereby at least one subsection of the honeycomb structure is heated to such a degree that the subsection reaches a temperature of between 800° C. and 1200° C. after 5 to 30 seconds. The metallic foils are interconnected in a subsection using a commercial jointing process. A device for producing metallic honeycomb bodies using at least one radiant heater is used in the process.

Abstract: A method for the production of pistons having depression edge armoring for internal combustion engines, in which a more heat-resistant armoring ring, in comparison with a forged piston blank having a combustion depression, is connected with the piston blank in the region of the depression edge. The method comprises the following steps: a first piston blank is set on a projection of the armoring ring in the region of the depression edge; the armoring ring is connected with the first piston blank by friction-welding; a second piston blank is set onto the projection of the armoring ring, in such a manner that the two piston blanks do not touch; the second piston blank is connected with the armoring ring by means of friction-welding; a the armoring ring is cut between the piston blanks, and the pistons are given their final shape by a cutting work method.

Abstract: The invention relates to a method for manufacturing tubes and profiles with variable wall thickness over the length. The method comprises the steps of flexible rolling of continuous material strip with variable thickness in the longitudinal direction of the strip material to a final wall thickness which is continuously reduced with respect to the original wall thickness, reshaping the material strip to form a continuous tube or profile and cutting to length individual tube or profile pieces from the continuous tube or profile.

Abstract: A vehicle shaft has a rigid intermediate portion with a shaft journal welded to each of the two ends of the shaft portion. The shaft journal and/or the intermediate portion are/is provided with a material thickness reduction within a distance a from the contact surfaces which is less than substantially half the material thickness at the contact surfaces, in order to guide the force flow thorough the weld seam. During manufacture of such vehicle shafts, the mutually abutting contact surfaces are laser-welded to form a weld seam which can fully penetrate the material of the shaft journals and the intermediate portion respectively, whereby the concentricity and parallelism of the two journals will be within predetermined dimensional tolerances after the welding and cooling of the material. The arrangement has an induction heater which surrounds the shaft journal and is movable axially so that, after completion of heating, it moves to free the shaft journals welded to the shaft portion.

Abstract: A method of aligning and duplicating alignment includes welding a washer over a larger opening in a hinge once in an aligned position relative to a vehicle door. The door is mounted into an alignment fixture and the hinges are installed over threaded studs extending from the door. The washer is placed onto the threaded stud and tightened against the hinge, covering the larger opening in the hinge. The larger opening in the hinge allows movement of the hinge relative to the door for alignment. The washer defines an opening with a smaller opening sized to provide relatively little clearance for the threaded stud, and thereby maintain alignment between the door and hinge. The washer is permanently attached by a welding operation to allow duplication of door hinge alignment during reassembly.

Abstract: A friction stir rivet is rotated and driven through a first fusible workpiece into an engaged second fusible workpiece, causing local portions of the first and second workpieces to plasticize. A slideable cap contacts the exposed surface of the first workpiece shortly after the process begins. The contact causes the cap to act as a retaining element, limiting the escape of plasticized material from stir site. Once the rivet is driven into the first and second workpieces, rotation ceases and the plasticized material hardens around the rivet. A weld is thus created, joining the workpieces and encompassing the rivet, which provides additional mechanical strength.

Abstract: The present invention provides a method of joining a sheet metal part to a metal tube to form an assembly. In an overlapping configuration, the parts are held together under a clamping force while a self-piercing rivet is driven through the assembly by a welding electrode. The rivet pierces and passes through the sheet metal part and then through at least substantial portion of the metal tube to thereby form a mechanical interlock. An electrical current is then applied to this mechanical retention to melt a portion of the rivet as well as a portion of the metal surrounding the joining region. The flow of electrical current is then stopped after several welding cycles where the now melted material is allowed to solidify upon cooling, thereby forming a weld.

Abstract: A process for molding an infant safety seat body for vehicles includes the steps of forming a contoured seat frame, disposing the contoured seat frame in a mold having the shape of the infant safety seat body, pouring foam into said mold and polymerizing the foam to form a cushion substrate, and stripping the foam from the mold.

Abstract: A low temperature target and backing plate bonding process and assemblies made thereby. A plurality of male projections (8) are formed in one member (2) of the assembly with a plurality of corresponding female recesses (9) formed in the other member (4). The assembly is bonded by conventional techniques around the peripheral boundary (25) that surrounds the male and female portions (8,9). The assembly is then pressure consolidated at low temperature so that the projections (8), circumscribed by the bonded zone, are force fit into the female recesses (9).

Abstract: A connection or weld attachment and method are disclosed for use in connecting a first structural member with a second structural member. An end plate is preferably attached to one end of the first structural member. The end plate and first structural member may then be attached by mechanical fasteners and at least one weld to the second structural member. A railway car having an underframe defined in part by a pair of side sills and a plurality of crossties may be formed with this mechanical connection. The end plate may be attached to a first leg which is in turn attached to the respective crosstie. The first leg preferably increases in width extending from the crosstie to the end plate. The mechanical fasteners are preferably disposed at opposite ends of the weld to minimize possible fatigue cracking and to increase the life of the associated connection.

Abstract: A friction stir rivet is rotated and driven through a first fusible workpiece into an engaged second fusible workpiece, causing local portions of the first and second workpieces to plasticize. A slideable cap contacts the exposed surface of the first workpiece shortly after the process begins. The cap acts as a retaining element limiting plasticized material from escaping during the process. As the rivet is further driven into the members the cap slides up the rivet and actuates an angled stirring member to increase the stir radius around the body of the rivet. Once the rivet is driven into the first and second workpieces, rotation is stopped and the plasticized material cools and hardens around the rivet, creating a weld joining the workpieces and encompassing the rivet, which provides additional mechanical strength.

Abstract: The invention concerns a method for making identity cores for ultrasound seals. Each core comprises a chip consisting of a brazed stack of metal disks 1 bearing at least one notch 3, the resulting identity being defined by the number, the size and the random angular position of the various notches in the stack and by the unpredictability of the brazing. The invention is characterized in that the notched disks 1 provided with a central hole 2 are first stacked in large numbers in a tubular metal sheath 4 with a circular cross-section corresponding to said disks 1. The stack is then axially compressed in the sheath 4 and a brazing bead 7 is inserted in the channel constituted by the assembly of aligned central holes 2. After brazing in a vacuum oven, the two ends of the sheath are eliminated and the resulting column is segmented perpendicularly to its axis into a series of individual identity chips 8 of predetermined thickness.

Abstract: In attempting to reduce deformity when joining vehicle frame components, a riveting/brazing process has been proposed. This process includes joining tubular members, such as hydroformed parts, by cutting at least one flange into one end of a first body member, shaped in conformance with the surface of a second body member. Location holes are formed into each flange as well as into the surface of the second member in suitable alignment with each other. A brazing filler material is fixed into a side of the flange, usually within a pocket, intending to lie on the surface of the second member when the two structures are attached. The flange(s) are initially attached to the surface of the second member by means of a rivet to formed an actual vehicle body assembly. Heat is then applied to the assembly to form a brazed T-joint.

Abstract: A method of attaching metal members, including placing the metal members in contact with each other and fastening them with a metal fastener having a central axis wherein the metal fastener includes an elongated portion having a substantially constant cross-sectional area at any cross-section taken along a length of the elongated portion perpendicular to the axis of the fastener and includes a topographically varying outer surface. The fastener is driven through the metal sheet and into the metal substrate during rotation of the fastener thereby inducing friction between the fastener, the sheet and the substrate for locally melting the members to form a flowable material that solidifies for attaching the members, the flowable material and the fastener together.

Abstract: An engine fuel injector body is assembled using a furnace brazing method to provide structural and hermetic internal joints at interior locations with minimum size and processing. The method of assembling an injector with such an internal hermetic and structural joint may include the steps of providing an annular body member with an annular inner recess having an inner cylindrical surface, forming an annular end recess adjoining the cylindrical surface, fitting a tubular member into the inner recess of the body member with an outer surface of the tubular member engaging the cylindrical surface of the inner recess, placing a brazing ring in the end recess of the body member adjacent the tubular member, and furnace brazing the members together to form the internal hermetic and structural joint. Additional joints may be joined during the same brazing step.

Abstract: A process is for producing a circumferentially closed hollow profile, which is of frustoconical form in sections, from a sheet-bar blank. To produce hollow profiles of this type, the sheet bar is cut to size so that a blank with a rectangular section and a ring segment, the summit of which adjoins the center of one side of the rectangle, while its outer arc, which faces the rectangle, is of approximately the same length as the length of the side of the rectangle, is formed, sheet-bar material also being left on the blank outside the summit, between the ring segment and the side of the rectangle, this material joining the ring segment with the side of the rectangle integrally at all locations and also joining the corners of ring segment and rectangle which are closest together, so as to form a rounded edge contour. Then the side edges of the blank are bent into abutment with one another about the longitudinal center axis of the blank.

Abstract: A process for manufacturing a sidewall for a trailer in the shape of a trapezoid having a right edge and a left edge of differing lengths and the top edge perpendicular to the right and left edges. A first rectangular sheet has lengths of a top and a bottom edge equal to a desired length of the sidewall. The second rectangular sheet is fabricated with top and bottom edges having a sufficient length so that right and left edges of the second sheet extend beyond the right and left edges of the first sheet. The second rectangular sheet is placed either on top of or underneath the first sheet so that the second sheet slopes downward either from the right to the left or from the left to the right at an angle with respect to the first sheet. The second rectangular sheet is welded to the first rectangular sheet along the entire length where the first rectangular sheet and the second rectangular sheet overlap thereby forming a seam.

Abstract: Improved joints for cryogenic liquid-containing tanks are disclosed. The joints include a support plate, a lower arm mounted on the support plate, an upper arm mounted on the support plate spaced from the lower arm, and tank skins extending into the space between the lower and upper arms. Sealing layers are provided between the tank skins and the joint arms. The joints are particularly useful for space launch vehicle cryogenic liquid propellant tanks which must be lightweight, withstand high structural loads and maintain leak-free conditions.

Abstract: Automated method and machinery for fabricating a wrought-iron fence panel. The machinery includes (a) automated programmable machinery for welding vertical pickets to horizontal runners to form a fence panel; (b) automated programmable machinery for straightening the fence panel; (c) automated programmable machinery for washing the fence panel; (d) automated programmable machinery for drying the fence panel; (e) automated programmable machinery for painting the fence panel; and (f) automated programmable conveyor machinery for conveying the vertical pickets, the horizontal runners, and the fence panel from station to station.

Abstract: A method of producing an encased honeycombed body, in particular a supporting body of a catalytic converter, includes the steps of producing a honeycombed body by stacking and/or winding sheet metal layers, of which at least some are structured sheet metal layers, so that the honeycomb body has channels through which a fluid can flow. A sleeve is introduced into a tubular jacket. The sleeve is smaller in the axial direction than the axial length of the honeycomb body and the tubular jacket. The sleeve has an outer circumferential surface which substantially bears against a part of the inner wall of the tubular jacket. The honeycomb body is introduced into the tubular jacket and into the sleeve and is connected to the tubular jacket and the sleeve. If required, the tubular jacket may also be connected to the sleeve.

Abstract: An apparatus and method are provided for initially performing a heat treatment process on a closed channel structural member to facilitate the subsequent performance of a magnetic pulse welding process so as to manufacture a vehicle frame component or a portion of a vehicle frame assembly. Initially, a workpiece is provided that is preferably formed from a closed channel structural member having a circular or box-shaped cross sectional shape. The workpiece is subjected to a scanning heat treatment process, wherein the workpiece is heat treated in a continuous and longitudinal manner from one end to the other. Preferably, the workpiece is supported vertically during the scanning heat treatment process to prevent the shape thereof from becoming distorted. The scanning heat treatment process is preferably a retrogression heat treatment process, wherein the workpiece is rapidly heated to a sufficient temperature that provides for full or partial softening thereof, followed by relatively rapid cooling.

Abstract: A method is provided for assembling a pole piece into an internal fuel passage of a fuel injector. The assembly method includes the steps of: (a) providing an endoskeletal injector tube, where the injector tube provides the fuel passage for the fuel injector; (b) forming at least one depression into an outer surface of the injector tube; (c) inserting an injector valve into the injector tube; (d) inserting the pole piece into the injector tube, wherein the pole piece is adjustable thereafter; and (e) affixing the pole piece within the injector tube, where an outer surface of the pole piece is in contact with an inner surface of the injector tube corresponding to the depressions, thereby creating a spring fit between the pole piece and the tube.

Abstract: A method of fabricating an aircraft leading edge nose structure includes the following steps. Parallel strengthening members are welded onto a flat planar outer skin sheet. Two forming tool members having appropriately shaped outer contours contact the inner surfaces of the strengthening members, and are then pivoted and shifted toward each other so as to bend the outer skin sheet into a parabolic shape along the curved contour defined by the forming tool members. The resulting bent outer skin sheet with the strengthening members welded thereon is secured into a negative mold. To provide boundary layer suction, a perforated throttling sheet, inner ribs, and a non-perforated inner skin sheet may be successively secured by sealant and blind rivets onto the pre-bent structure of the outer skin sheet and the strengthening members. The finished structure is then removed from the mold.

Abstract: A spray gun valve assembly is disclosed together with a method for manufacturing the same, wherein a spray gun valve plug (e.g., made of materials such as a tungsten carbide alloy) is secured to an end of an elongate valve stem (e.g., made of stainless steal) by resistance welding techniques. A holder component may act as an intermediate component between the plug and the valve stem, wherein the plug is resistance welded to the holder, and the holder is secured to the end of the valve stem. The method for securing the holder and the valve stem components can provide both a weld and a mechanical lock to secure these components together.

Abstract: A method for fabricating an automotive spaceframe using Electromagnetic Pulse Forming (EMF) or Magnetic Pulse Welding (MPW) techniques. The spaceframe can be either an all aluminum structure or a combination of dissimilar materials, such as aluminum and steel. The welding or forming methods can include the use of split coils or split inductors that allow for ease of access to the joints to be bonded in the spaceframe.

Abstract: In a method for manufacturing a crossmember for stiffening an instrument panel of a motor vehicle, the crossmember that is to be manufactured having at least two profiled segments, with cross sections differing from one another, arranged in axial prolongation, the smaller-cross-section profiled segment is arranged so as to overlap the larger-cross-section profiled segment over at least a partial length; and in the overlap region, the profiled segments are joined to one another in at least one direction perpendicular to the longitudinal direction by way of at least one stabilizing joining element.