Gm Global Technolgoy Operations, Inc.

David P Kelly

Pei-chung Wang

James Franklin Hengel

David R Sigler

Blair E Carlson

Michael J Karagoulis

Robert T Thornton

A resistive welding electrode includes at least a weld face constructed of a refractory-based material that exhibits an electrical conductivity that is less than or equal to 65% of the electrical conductivity of commercially pure annealed copper as defined by the International Annealed Copper Standard (IACS). A method of using the resistive welding electrode to resistance spot weld a workpiece stack-up that includes an aluminum alloy workpiece and steel workpiece that overlap and contact each other at a faying interface is also disclosed.

Resistive welding electrode and method for spot welding steel and aluminum alloy workpieces with the resistive welding electrode

This invention provides a method of welding a cage and nut combination to a surface of a workpiece using a welding electrode as a holding and locating member for the cage and nut. The cage and nut are placed, upside-down, in a recess formed in the welding tip of a lower electrode which is positioned vertically with its tip up. The workpiece backed by an opposing welding electrode are positioned above the electrode holding the inverted cage. The inverted cage and workpiece are pressed together along a vertical axis and electrically welded. The lower electrode with its recess serves to accurately locate the inverted cage with its weld material projections for uniform welding contact with the surface of the workpiece for more efficient welding setup and an improved welded bond between the cage, retaining a nut, and the workpiece.

Method of welding a cage and nut assembly to a workpiece

This invention provides a method of welding a flange nut to a workpiece surface using an improved design of a welding electrode. The electrode comprises a parts-receiving recess adapted to receive a stem portion of the nut, while maintaining a clearance between the recess and the stem. This clearance allows electrical current to be directed toward the flange portion of the nut. As a result, electrical contact between the workpiece and projections underlying the flange is greatly improved, thereby produce higher quality spot welds and increasing the life of the electrode tip.

Projection welding of flanged weld nut

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.

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Rochester Hills, MI, United States of America

David P Kelly