Delphi Technologies, Inc.

Desra N Herbst

Venkatasubramanian Ananthanarayanan

Dharmendra M Ramachandra

Kevin J Szeszulski

Ventakatasubramanian Ananthanarayanan

Welded structures having a first and a second member formed from sheet metal, tubes, and similar shapes, are economically fabricated through use of a method for joining a second member to a first member having a folded rim extending therefrom. The folded rim defines an air gap within the folded rim. The first and second members are joined together by forcing the folded rim against the second member under sufficient pressure to flatten the folded rim to a point that there remains substantially no air gap inside the folded rim, and resistance welding together the first and second members. The second member and the rim respectively define faying surfaces thereof. The air gap inside the folded rim extends generally parallel to the faying surfaces. The faying surfaces of the rim and second member are forced against one another by applying pressure through the folded rim in a direction generally perpendicular to the faying surfaces. While applying pressure, a first level of electrical current may be passed through the first and second members for softening the rim by electrical resistance heating and causing the softened rim to deform against the second member. Pressure is maintained, and a second level of electrical current, higher than the first level of current, is applied for a time sufficient to at least partially melt the folded rim and form a deformation resistance weld between the first and second member.

Deformation resistance welding of sheet metal, tubes, and similar shapes

A first method for metallurgically attaching together two members. A first member is obtained having a through hole and having a longitudinally-projecting flange surrounding the through hole. A second member is obtained having a transversely-projecting annular rim. The second member is at least partially positioned in the through hole of the first member with the flange of the first member projecting away from the rim. The first and second members are resistance welded together, wherein after the weld is created, the rim of the second member is seated on the first member. In an other method, which is similar to the first method, the second member has no rim.

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Dayton, OH, United States of America

Desra N Herbst