Abstract: Methods are provided for joint performance validation and include preparing a coupon from a blank by bending the blank to have a pair of legs disposed at substantially ninety degrees relative to each other. Another coupon is prepared by forming an opening in a segment of another blank and bending the segment approximately ninety degrees. The segment is disposed adjacent an end of the second blank. A test sample is prepared by joining the coupons together at a joint with a leg attached to the segment approximately at a center of the leg. The test sample is subjected to a force test to generate data for the performance validation.

Abstract: A lap shear test fixture and method of use to test the performance of the weld interface in welded thermoplastic composite parts such as infrared welded or resistive implant welded or adhesive bonded composite parts. The specimens to be tested are provided from production-ready parts with typical geometry. The test fixture has at least two aligned blocks with at least two lateral support blocks that operably hold the specimen including two welded substrates. The test is performed in compression-mode at a predetermined crosshead speed until the maximum load produced by a universal testing machine makes the weld interface between the two thermoplastic substrates fail in shear mode.

Abstract: A numerical simulation tool for progressive failure in laminates utilizes a low fidelity approach. The numerical model includes an enriched element that is initially in a low fidelity form. The enriched elements may increase fidelity by splitting locally to simulate an ongoing damage process such as delamination.

Abstract: Apparatus and methods related to umbilical bend-testing are described. For example, some embodiments may contain a three-level support structure, umbilical terminal locker, bending machine, compression testing device, and stress-strain collection system, and may be used for the bending fatigue endurance test for umbilical samples.

Abstract: Disclosed are assembly line equipment maintenance devices and methods. A maintenance cart is selectively engaged to a transport conveyor and integrated into a moving assembly line. The cart can include maintenance tools to refurbish robot end effector tools or replacement tools engageable by robot wrists. The maintenance or replacement tools can include a variety of maintenance equipment including weld tip dressing tools, weld force gauges, replacement weld guns, and test coupon disks.

Abstract: An improved header assembly and corresponding port assembly comprising a tensioning member, wherein the tensioning member is isolated and separate from the weld portion and is adapted to place a threaded portion between the header assembly and port assembly in tension and maintain such tension, and thus relieve tension from the weld, before and after welding, thereby increasing the lifespan of the header and port assemblies.

Abstract: A method and apparatus for installing a refractory material to a surface by inserting a nozzle and a neck of a welding gun through a channel in a refractory material, positioning the refractory material on the surface using the welding gun, firmly pushing the welding gun into the channel of the refractory material until the nozzle of the welding gun, an anchor embedded in the refractory material and the surface are in contact, welding the anchor of the refractory material to the surface with the welding gun, and removing the nozzle and the neck of the welding gun from the channel in the refractory material.

Abstract: A support for a thin element in an electrically conducting or semi-conducting material, one face of which is intended to be put into contact with a liquid or gas medium, the support has a first part provided with a central through-passage with a longitudinal axis, said passage including at least one first and one second portion with a different diameter connected to each other through a shoulder, said shoulder being intended for supporting said thin element; a second part penetrating into the passage with the end opposite to the one intended to be exposed to the liquid solution, capable of maintaining the thin element on the shoulder; and a seal between the thin element and the shoulder.

Abstract: A push test fixture having a cradle and a load pin is provided along with a test sample that reasonably represents the strength and quality of the original welds that hold the wrap wires and axial wires of the sample together. The test sample is placed in the push test fixture such that a particular weld on the test sample is aligned between the cradle and the load pin. A load is applied through the weld using the load pin, and a strength property such as the ultimate strength or the yield strength of the weld is determined. The cradle helps maintain the original, as-wrapped curvature of the wrap wire. The test samples can come, for example, from direct wrap filters or wire-wrap jackets. The strength property can be determined for at least every third wrap wire of the test sample.

Abstract: A push test fixture having a cradle and a load pin is provided along with a test sample that reasonably represents the strength and quality of the original welds that hold the wrap wires and axial wires of the sample together. The test sample is placed in the push test fixture such that a particular weld on the test sample is aligned between the cradle and the load pin. A load is applied through the weld using the load pin, and a strength property such as the ultimate strength or the yield strength of the weld is determined. The cradle helps maintain the original, as-wrapped curvature of the wrap wire. The test samples can come, for example, from direct wrap filters or wire-wrap jackets. The strength property can be determined for at least every third wrap wire of the test sample.

Abstract: A combination of a bearing component and a sensor, wherein: (a) at least a portion of the bearing component is formed from a bearing steel; (b) the sensor comprises a sensor element and a support therefor; (c) at least a portion of the support is formed from a low carbon steel comprising no more than 0.2 wt. % carbon or from nickel or an alloy thereof or from titanium or an alloy thereof; and (d) the bearing component and the support are welded or brazed to one another via said respective portions.

Abstract: A method and apparatus for installing an insulation material to a surface by inserting a nozzle and a neck of a welding gun through a channel in an insulation material, positioning the insulation material on the surface to be insulated using the welding gun, firmly pushing the welding gun into the channel of the insulation material until the nozzle of the welding gun, an anchor embedded in the insulation material and the surface are in contact, welding the anchor of the insulation material to the surface with the welding gun, and removing the nozzle and the neck of the welding gun from the channel in the insulation material. A method and apparatus for testing the integrity of a weld between an anchored insulation material, a surface and a nozzle of a welding gun. A special tool for testing the integrity of the weld between the anchored insulation material and a surface.

Abstract: A method to diagnose a failed weld in a welding process includes monitoring a location of a weld created on a plurality of work pieces, diagnosing the weld as a failed weld based on said location with respect to a closest edge of one of the work pieces, and identifying said failed weld based on the diagnosing.

Abstract: A method of testing a fusion weld for a shaft includes producing two shaft subsections, wherein the shaft subsections are symmetrical and faun a cylinder coaxially along the axis of rotation. Core regions of each shaft subsection are removed in order to produce open recesses in the cylinder within remaining tubular webs. The two shaft subsections are positioned coaxially one on top of the other, wherein the two remaining webs are mutually adjacent and the two open recesses form a hollow space. A first tubular ring seam is produced by narrow-gap arc welding and in one of the two shaft subsections a passage from outside into the hollow space is produced. Further, a quality of the first tubular ring seam within the hollow space during and/or after the welding operation is evaluated by a detection device or radiation source which is introduced through the passage into the hollow space.

Abstract: A material specimen is provided. The material specimen for tensile or HCF tests includes two welds arranged opposite one another on the specimen which do not touch. The welds are arranged symmetrically in relation to a plane or mirror symmetrically in relation to a longitudinal axis of the specimen which extends parallel to the line of effective force.

Abstract: A method for testing the integrity of a weld on a pipe includes the application of an axial stress on the weld during the integrity test. Ali assembly for performing the method is also provided, wherein a pair of circumferential supports are provided on the pipe on opposite sides of the weld, and between which extend axial force applying devices. In one aspect, the invention is used to test a weld securing a flange to a pipe. The invention also provides novel circumferential clamps for securing to the exterior of pipes.

Abstract: In a manufacturing method of a pressure detector, a first member that includes a sensing portion for outputting an electric signal in accordance with a pressure, a second member that includes a pressure-receiving diaphragm, and a pressure transmission member are prepared. The pressure transmission member is disposed between the sensing portion and the pressure-receiving diaphragm and the first member and the second member are welded in a state where the pressure is applied from the pressure-receiving diaphragm to the sensing portion through the pressure transmission member. One of the first member and the second member are strained so that a preliminary load, which is applied from the pressure-receiving diaphragm to the sensing portion through the pressure transmission member in a state where no external pressure is applied to the pressure-receiving diaphragm, meets a predetermined value.

Abstract: A weld inspection device is disclosed. The weld inspection device comprises a first annular engagement portion surrounding a central axis and a second annular engagement portion. The first annular engagement portion has a first holed segment extending circumferentially around an outer edge of the first annular engagement portion and having a first hole adapted to receive a threaded member and a standoff segment extending in a first direction along the central axis from the first holed segment, the standoff segment having a concavity. The second annular engagement portion surrounds the central axis and has a second holed segment extending circumferentially around the central axis and having a second hole adapted to receive and threadedly engage a threaded member, and a retaining flange extending radially inward toward the central axis.

Abstract: A fatigue life estimating method for a spot welded structure is provided comprising the steps of providing a shell model of a spot welded structure for a finite element method analyzing process, calculating the nominal structural stress on a nugget as the center of the spot welded structure using a disk bending theory and a two-dimensional elastic theory of the elastodynamics with the partial loads exerted on the nugget and the deflection on the circumference of a circle, D in diameter, in which the nugget is located, which have been calculated by the finite element method analyzing process of the shell model, and estimating the fatigue life of the spot welded structure from the nominal structure stress. According to the method, the fatigue life of the spot welded structure can be estimated easily, readily, and accurately.

Abstract: Positions of predetermined spots in a frame of a motorcycle are determined by sensing all the predetermined spots in one direction from a front side or a rear side of the frame of the motorcycle by a sensing device.

Abstract: A method of determining deterioration of pressurizing performance of a spot welding, the method having: obtaining reference data that reflect a dynamic state of a servo motor in a case where a movable side electrode tip is operated normally and a wok piece is pressurized by a specified pressurizing force; performing data processing on the reference data to extract a reference characteristic value; obtaining diagnostic data that reflect a dynamic state of the servo motor in a case where a operational state of the movable side electrode tip changes and the work piece is no longer pressurized by a specified pressurizing force; performing data processing on the diagnostic data to extract a diagnostic characteristic value; and determining deterioration of pressurizing performance of the spot welding gun based on the reference characteristic value and the diagnostic characteristic value.

Abstract: A portable multi-axis load confirmation tool having a rotating ball on the end thereof follows a three-dimensional weld program path therewith. The ball reacts to an internal load cell for verifying weld program path dynamics before an actual program is run with friction stir welding tools. The load cell is connected to instrumentation electronics converting a load cell signal to a digital readout and comparing the load cell signal to weld program load requirements. The tool integrates into a tool holder loaded on a friction stir welding spindle for simulating an actual friction stir welding tool.

Abstract: In a manufacturing method of a pressure detector, a first member that includes a sensing portion for outputting an electric signal in accordance with a pressure, a second member that includes a pressure-receiving diaphragm, and a pressure transmission member are prepared. The pressure transmission member is disposed between the sensing portion and the pressure-receiving diaphragm and the first member and the second member are welded in a state where the pressure is applied from the pressure-receiving diaphragm to the sensing portion through the pressure transmission member. One of the first member and the second member are strained so that a preliminary load, which is applied from the pressure-receiving diaphragm to the sensing portion through the pressure transmission member in a state where no external pressure is applied to the pressure-receiving diaphragm, meets a predetermined value.

Abstract: A method of determining deterioration of pressurizing performance of a spot welding, the method having: obtaining reference data that reflect a dynamic state of a servo motor in a case where a movable side electrode tip is operated normally and a wok piece is pressurized by a specified pressurizing force; performing data processing on the reference data to extract a reference characteristic value; obtaining diagnostic data that reflect a dynamic state of the servo motor in a case where a operational state of the movable side electrode tip changes and the work piece is no longer pressurized by a specified pressurizing force; performing data processing on the diagnostic data to extract a diagnostic characteristic value; and determining deterioration of pressurizing performance of the spot welding gun based on the reference characteristic value and the diagnostic characteristic value.

Abstract: A portable multi-axis load confirmation tool having a rotating ball on the end thereof follows a three-dimensional weld program path therewith. The ball reacts to an internal load cell for verifying weld program path dynamics before an actual program is run with friction stir welding tools. The load cell is connected to instrumentation electronics converting a load cell signal to a digital readout and comparing the load cell signal to weld program load requirements. The tool integrates into a tool holder loaded on a friction stir welding spindle for simulating an actual friction stir welding tool.

Abstract: Method for evaluating the fatigue strength of welded joints produced by melting an alloy using a specified welding technique, which method comprises the following steps: a statistically significant number N of specimens are produced with a welded joint using said welding technique; each of the specimens is subjected to cyclic fatigue tests, with an alternating stress a, until failure; the size of the relevant defect appearing in the fracture plane of the specimens is measured by fractography; a range of defect dimensions for which the probability of measuring by fractography a defect outside the range is less than a predetermined level of probability t is determined from the measured sizes; and the lowest stress ?min liable to cause the specimen to fail with a level of probability t is determined from this range.

Abstract: A scanning probe microscope (SPM) based measuring technique for measuring surface features of a sample fits a curve to a family of feature edge points acquired as a result of an SPM scan of the surface feature. If two curves are fit on opposed edges of the feature of interest, the maximum or minimum distance between those curves can be determined to ascertain a dimension of interest such as a maximum via width, a minimum line width, etc. The scan is preferably a relatively low-resolution scan in the Y direction, typically having 8-12 scan profiles passing through the feature of interest low-resolution, which is about half that typically used by prior techniques. The low-resolution scan can be performed relatively rapidly and with high repeatability. Repeatability is also higher than with prior techniques, and the level of repeatability is relatively insensitive to the resolution in the Y direction.

Abstract: Method for evaluating the fatigue strength of welded joints produced by melting an alloy using a specified welding technique, which method comprises the following steps: a statistically significant number N of specimens are produced with a welded joint using said welding technique; each of the specimens is subjected to cyclic fatigue tests, with an alternating stress a, until failure; the size of the relevant defect appearing in the fracture plane of the specimens is measured by fractography; a range of defect dimensions for which the probability of measuring by fractography a defect outside the range is less than a predetermined level of probability t is determined from the measured sizes; and the lowest stress ?min liable to cause the specimen to fail with a level of probability t is determined from this range.

Abstract: An apparatus and method for testing weld integrity is disclosed which is portable, self-contained, adaptable for field use in most locations, and can verify the integrity of attachment welds. The testing apparatus includes a cylinder or cylinders, attachable to the desired object to be tested on one end and to a cross bar on the other end, support beam or beams which, along with the cylinder or cylinders, support the test apparatus, a supply for pressurized fluid, and a control manifold for flow direction and pressure measurement. The pressurized fluid moves the cylinder shaft creating a load on the test piece. As the fluid pressure increases, the cylinder shafts extend or retract and exert a required load on the test piece. The test piece is then inspected for breakage or damage such as deformation or attachment weld cracking.

Abstract: Two parts which form a device and are joined together according to the related art are joined in a complex manner and require additional elements to produce a tight joint. A device (1) is described which has two parts (3, 6), has welding pockets (9) which are capable of receiving material during the welding operation for producing a joint.

Abstract: In the method for evaluating a welded part, it is performed to make an inspection press member press the welded part for connecting a plurality of wires with each other to apply a predetermined compressive load on the welded part. Next, it is performed to measure an amount of strain of the welded part when it is subjected to the compressive load. The evaluation of the welded part in welding condition is carried out by judging whether or not the measured amount of strain is within a predetermined range.

Abstract: A non-destructive plastic butt weld inspection method in which the weld bead 42 is removed from an exterior surface of a weld zone region 44 of a butt weld and the weld zone region 44 is heated to a temperature sufficient to visualize the weld zone 44. After heating, defective joints are readily identified by the appearance of a bond line 40 in the weld zone 44 while satisfactory joints merely show the weld zone 44 with no evidence of a bond line 40. Surface irregularities such as ridges 46 and indentations 48 may also form in the weld zone during the heating step.

Abstract: An apparatus and method for testing weld integrity is disclosed which is portable, self-contained, adaptable for field use in most locations, and can verify the integrity of attachment welds. The testing apparatus includes a cylinder or cylinders, attachable to the desired object to be tested on one end and to a cross bar on the other end, support beam or beams which, along with the cylinder or cylinders, support the test apparatus, a supply for pressurized fluid, and a control manifold for flow direction and pressure measurement. The pressurized fluid moves the cylinder shaft creating a load on the test piece. As the fluid pressure increases the cylinder shafts extract or retract and exert a required load on the test piece. The test piece is then inspected for breakage or damage such as deformation or attachment weld cracking.

Abstract: A method and sheet-like sensor for measuring stress distribution including a grid of members which change in resistance when subjected to strain, the members intersecting at internal nodes and intersecting at boundary nodes at the periphery of the grid defining a plurality of legs. An analyzer is electrically connected only to the boundary nodes and configured to calculate any change in resistance in all of the legs based solely on the measured resistance of the legs between the boundary nodes.

Abstract: In the method for evaluating a welded part, it is performed to make an inspection press member press the welded part for connecting a plurality of wires with each other to apply a predetermined compressive load on the welded part. Next, it is performed to measure an amount of strain of the welded part when it is subjected to the compressive load. The evaluation of the welded part in welding condition is carried out by judging whether or not the measured amount of strain is within a predetermined range.

Abstract: Resistance welding is a process used to join metallic parts with electric current. A weld nugget is formed as the pieces are melted together. This weld nugget is normally circular in shape. Most welds are expected to be of a specific size based on a specific material thickness. The thinner the material, the smaller the weld nugget required. This reference tool allows the inspector to validate that the welds exceed the minimum requirement without the need to take measurements or the need to check specification sheets or use math skills. This tool also provides a visual and physical check of the weld nugget to verify compliance with the specification for the weld based on the material thickness.

Abstract: This invention has as its object to facilitate determination of a weld strength of welded target members when a plurality of metal members are welded. In order to achieve this object, when a plurality of metal members are welded, a weld strength of the welded target members is determined on the basis of the state of a lower bead.

Abstract: An apparatus and method for testing weld integrity is disclosed which is portable, self-contained, adaptable for field use in most locations, and can verify the integrity of attachment welds. The testing apparatus includes a cylinder or cylinders, attachable to the desired object to be tested on one end and to a cross bar on the other end, support beam or beams which, along with the cylinder or cylinders, support the test apparatus, a supply for pressurized fluid, and a control manifold for flow direction and pressure measurement. The pressurized fluid moves the cylinder shaft creating a load on the test piece. As the fluid pressure increases the cylinder shafts extract or retract and exert a required load on the test piece. The test piece is then inspected for breakage or damage such as deformation or attachment weld cracking.

Abstract: There is provided a method of testing a joint formed by bonding of two tubulars, which method comprises the steps of holding a first tubular; applying a force to displace a second tubular relative to the first tubular; and removing the force. The final position of the second tubular is then compared with the position which it occupied prior to the application of the force by means of a sensor mounted remotely from the second tubular.

Abstract: A tensile test apparatus and method for testing a circumferential weld on a tubular member wherein the tube region of the weld is completely supported by a mandrel and the tubular specimen is gripped on both sides of the weld along the specimen's longitudinal length with a very small separation distance between the tensile test grips. If there are any non-bonded defects in the weld, they are captured by the weld fracture surface as mesa or void features with an orientation different from that of a well bonded region.

Abstract: This invention has as its object to facilitate determination of a weld strength of welded target members when a plurality of metal members are welded. In order to achieve this object, when a plurality of metal members are welded, a weld strength of the welded target members is determined on the basis of the state of a lower bead.

Abstract: A fixture is provided for testing the shear strength of a longitudinal weld which interconnects a plurality of planar blanks forming a tailor welded blank. The fixture includes a first pair of triangular shaped face plates connected to one side of the tailor welded blank and a second pair of triangular shaped face plates connected to the other side of the tailor welded blank. Each of the face plates includes a transverse edge which extends across the longitudinal weld connecting the planar blanks. The fixture further includes each of the transverse edges having a first portion and a second portion spaced from and parallel to the first portion. The fixture also includes an isolation portion interconnecting the first and second portions of the transverse edges adjacent the longitudinal weld for isolating a portion of the weld whereby the isolated portion of the weld is tested for shear resistance by applying a tensile load to the first and second pair of face plates.

Abstract: A method and system for testing joints which join one member to another member are disclosed. The method and assembly are capable of non-destructively testing joints which join such members without damaging the members or the joints.

Abstract: This need is met by the present invention wherein structural stress in a fatigue-prone region of a structure is determined by using the nodal forces and displacement values in the fatigue-prone region, or equilibrium-equivalent simple stress states consistent with elementary structural mechanics in the fatigue-prone region. The determination is substantially independent of mesh size and is particularly well-suited for applications where S-N curves are used in weld fatigue design and evaluation, where S represents nominal stress or stress range and N represents the number of cycles to failure. The present invention is directed to structural stress analysis through various combinations of modeling, calculation, and direct measurement schemes.

Abstract: In testing a method for non-destructive testing of a welded assembly which includes a plurality of strands of electrical conductors which are joined together into a bundle by ultrasonic welding, a defined testing force is introduced into two or more shell surface segments of the welded assembly in directions oriented substantially towards each other or substantially to a comon intersection. For carrying out the testing method, a testing device and a welding machine which constitute such a testing device are provided.

Abstract: A sheet metal component, obtained by press-forming a one-piece metal sheet comprised of two metal sheets into a desired shape, has an expanding portion having an external appearance varying in dependence on a weld state of a weld portion of the one-piece metal sheet at which the two metal sheets are welded at their confronting ends. In manufacturing the sheet metal component, the one-piece metal sheet is transferred between upper and lower dies of a pressing machine and is positioned such that its metal sheet section including part of the weld portion is disposed between a punch formed in the lower die and a recess formed in the upper die so as to face the punch. The metal sheet section is pressed by the punch to be subject to plastic deformation, whereby the expanding portion is formed.

Abstract: A tensile test apparatus and method for testing a circumferential weld on a tubular member wherein the tube region of the weld is completely supported by a mandrel and the tubular specimen is gripped on both sides of the weld along the specimen's longitudinal length with a very small separation distance between the tensile test grips. If there are any non-bonded defects in the weld, they are captured by the weld fracture surface as mesa or void features with an orientation different from that of a well bonded region.

Abstract: A method for nondestructively and accurately determining the stress of a fabricated semiconductor chip soldered, brazed or otherwise bonded to a submount using optical microscopy and finite element analysis. Deformations on a top surface of the semiconductor chip are first examined using optical microscopy. The deformations are then correlated using finite element analysis to the stress on the semiconductor chip caused by the soldering process. If the stress is determined to be within an acceptable range of measurement, then the semiconductor chip will have been properly soldered to the submount and can be used.

Abstract: In an automated welding machine, where a flow of liquid coolant is supplied to welding components on the machine from a source of coolant and then returned to the source of coolant, a safety system is provided that shuts down the flow of coolant in the event of a fault. Faults are detected by a supply sensor and a return sensor for measuring the flow rates of coolant in the supply and return lines. A microprocessor is adapted to compare the supply flow rate and return flow rate and detect differences between the two rates. The difference between the detected rates as compared to a leak threshold value, and the microprocessor is adapted to generate a valve shutoff signal in the event the detected difference in flow rates exceeds the leak threshold value. A value in the supply coolant line is responsive to the valve shutoff signal to shutoff flow of coolant in response thereto.

Abstract: A testing module for testing the strength of the welding area on a PCB is disclosed. The testing module has a plurality of first plates each provided with a plurality of pressing plates adjustably mounted thereon and a plurality of second plates each provided with a plurality of supporting plates securely mounted thereon. Each of the pressing plates are located at the center of two adjacent supporting plates, such that a plurality of PCBs are able to be tested for the strength of the welding area at a time.