Tessonics Corporation

Chrysler Group LLC

Andriy M Chertov

Roman Gr Maev

Roman Maev

Frank J Ewasyshyn

John M Paille

John Paille

A method and apparatus for ultrasonic in-process monitoring and feedback of resistance spot weld quality uses at least one transducer located in the electrode assembly transmitting through a weld tip into an underway weld. Analysis of the spectrum of ultrasonic waves provides the operator with an indication of the size, thickness, location, dynamics of formation and quality of the spot weld. The method presents a fundamentally new physical approach to the characterization of the spot weld quality. Together with transmission mode it includes new modes of operation of ultrasonic probes such as a reflection mode and simultaneous use of transmission and reflection modes, and a new physical interpretation of the signal analysis results.

Ultrasonic in-process monitoring and feedback of resistance spot weld quality

An example electrode cap includes a bored portion of an electrode cap. The bored portion establishes a bore that extends longitudinally from one end of the electrode cap and terminates at a surface having a radius relative to the longitudinal axis. A tip portion of the electrode cap extends from the surface toward another end of the electrode cap. An example method of maintaining a focal point of an ultrasonic wave includes propagating an ultrasonic wave from a transducer through a bore and a tip portion of an electrode cap and receiving a reflection of the ultrasonic wave. The method further includes determining information about a welded area using the reflection and adjusting a radius of a surface of the electrode cap to position a focal point of the ultrasonic wave within the tip portion.

Electrode cap for ultrasonic testing

Growing community of inventors

Windsor, CA, United States of America

Andriy M Chertov