Thyssenkrupp Steel Europe Ag

Thyssen Krupp Ag

Thyssenkrupp System Engineering Gmbh

Azeddine Chergui

Andreas Niesen

Peter Cornelius

Thomas Ralle

Jürgen Goldmann

Jovan Berak

Mustafa Al

A welding electrode may comprise a welding electrode body and a welding electrode cap that is connected or connectable to the welding electrode body for making contact between the welding electrode and a component for producing a welded connection. The problem of achieving an efficient heating of the sandwich sheet to be welded in a compact layout with the fewest possible modifications of the welding electrodes used heretofore is solved in that an electrically conductive resistance element integrated, or which can be integrated, in the welding electrode and which is connected or connectable in an electrically-conductive manner to the welding electrode body and the welding electrode cap is provided for the heating of the component. Furthermore, a method and a device with the welding electrode and a use are disclosed.

Welding electrode, method, and device for welding sandwich panels

The invention relates to a method for joining at least one sandwich sheet to at least one functional element made of metal, wherein the at least one sandwich sheet has two metallic outer layers and a thermoplastic layer arranged between the metallic outer layers, wherein at least the region to be joined of the at least one sandwich sheet is heated in such a manner that the thermoplastic layer softens, the plastic layer is pushed out of the joining region by the outer layers being pressed together, and the outer layers of the at least one sandwich sheet are joined, in particular welded, to the functional element by an electric current flow between a first and a second electrode.

Integrated resistance welding of functional element and auxiliary element

The present disclosure concerns devices and methods for resistance welding sandwich sheets to other components. Many sandwich sheets include a thermoplastic material layer disposed between two metallic cover layers. The sandwich sheet and the other component may be secured relative to one another by a clamping arrangement. A region of the sandwich sheet to be welded may be heated by a preheating current to soften and displace the thermoplastic material layer when the cover layers are pressed together. With respect to the preheating current, a first electrode arrangement may at least temporarily contact an electrically conductive contacting region of the clamping arrangement such that the preheating current can flow via the clamping arrangement. The cover layers may be welded to the other component with a welding current via the first welding electrode of the first electrode arrangement and a second welding electrode of a second electrode arrangement.

Method and device for the resistance welding of sandwich sheets

Sandwich panels may include an intermediate thermoplastic layer disposed between two metallic cover layers. Some methods for welding a sandwich panel to a metallic component may involve heating a region of the sandwich panel with a preheating current so that the thermoplastic layer is softened and by compression of the cover layers is displaced from the welding region. A tack-welding current flowing between first and second welding electrodes may weld the cover layers together, and a welding current may be used to weld the metallic cover layers to the metallic component. In some cases, the first welding electrode may be in contact with one of the metallic cover layers, and the second welding electrode may be in contact with the metallic component. As a result, the sandwich panel may be joined to the metallic component in a short cycle time without blisters and faults arising in the sandwich component.

Multi-stage resistance welding of sandwich-type metal sheets

A method for resistance spot welding a metallic material to a sandwich material that includes a plastic core layer with two metallic cover layers may involve positioning a first electrode onto a surface of the metallic material, positioning an opposing second electrode onto a surface of the metallic cover layer that is apart from the metallic material, heating a region to be welded in such a manner that the plastic core layer in the region to be welded softens, moving the electrodes together to displace the softened plastic from the region to be welded until the two cover layers make contact with one another in a contact region, and welding the metallic cover layers to the metallic material in the contact region by a flow of electrical current across the first and second electrodes. A device by way of which a simple structure with a limited heat-affected zone is also disclosed for performing such methods.

Method for resistance spot welding of a sandwich material and corresponding device

Methods and devices for joining a composite panel, which may comprise a non-metallic intermediate layer disposed between two external metallic cover layers, to a further component are disclosed. The composite panel and the further component may be disposed so as to at least partially overlap. The object of economically and reliably joining composite panels may be achieved in that by way of a positioning unit, at least one auxiliary joining element is brought to bear on the composite panel and is fixed to the composite panel. The composite panel in a region of the at least one auxiliary joining element may be subsequently joined to the further component.

Joining using auxiliary joining elements

The present invention proposes a device, robot with such a device, punch for such a device and method for punching an opening into a lightweight metal sheet that has at least two metallic outer layers and at least one non-metallic core layer arranged between the metallic outer layers, the device having means for carrying out a relative movement of a punch with respect to the lightweight metal sheet and a quill with an integrated heat source, the punch being able to be heated up by the heat source.

Device for punching an opening into a lightweight metal sheet and a method for performing the same

Joining regions in sandwich sheets having a plastic core layer disposed between two metal cover layers are desirable for purposes of joining sandwich sheets to other components by, for instance, fasteners and/or welded joints. Methods and apparatuses for producing such joining regions in sandwich sheets allow for durably form-fitting and/or force-fitting joints between the sandwich sheets and other components. Some methods may involve displacing plastic material of the core layer of the sandwich sheet out of the region to be joined. A predetermined force may be exerted perpendicular to a surface of the region to be joined when the core layer of the sandwich sheet is heated so that the plastic material of the core layer is softened and at least partially displaced. In turn, the metal cover layers of the sandwich sheet may be brought into contact with one another in the region to be joined.

Method and apparatus for producing joining regions of composite sheets

Devices and methods for resistance-welding a metallic component to a sandwich sheet having a thermoplastic layer disposed between two metallic cover layers may involve heating a region of the sandwich sheet to be welded such that the thermoplastic layer softens. The cover layers of the sandwich sheet may then be compressed so as to displace the thermoplastic layer from the region of the sandwich sheet to be welded. Electrical circuitry may then be employed to interconnect the metallic cover layers and the metallic component by passing a current through a pair of electrodes positioned on opposing sides of a combination including the sandwich sheet and the metallic component.

Method and device for resistance welding of sandwich-type plates using a second electrical circuit

The invention relates to a method for the resistance welding of a metal sheet to a further metallic component, wherein the metal sheet is welded to the further component by a flow of electric current for welding in a circuit comprising the metal sheet, the further component, a first welding electrode and a second welding electrode, wherein the first welding electrode is in contact with the metal sheet and the second welding electrode, lying opposite the first welding electrode, is in contact with the further component on the side of the further component that is facing away from the metal sheet, wherein, in a first phase, the metal sheet is subjected at least for a time to a first force at least by the first welding electrode and, in a second phase, the metal sheet is subjected at least for a time to a second force at least by the first welding electrode during the flow of electric current for welding, the second force being lower than the first force.

Method and device for the optimized resistance welding of metal sheets

The invention relates to a method for producing a composite sheet metal part having at least one metallic region from a composite sheet metal blank which has two outer cover sheets of metal and at least one layer which is arranged between the cover sheets and consists of plastics material. The invention provides an apparatus and method by which complex formed composite sheet metal parts can easily be produced in a few steps and which still have metallic regions which can be used for joining to further parts.

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Dortmund, Germany

Azeddine Chergui