Magna International Inc.

John Edward Hill

Terence Anthony Devers

Gianfranco Gabbianelli

Terry Devers

Harish Mistry

A method for joining a first part formed of an aluminum material to a second part formed of a steel material by metal inert gas welding and cold metal transfer is provided. An aluminum filler material forms a fillet joint between the parts and provides a structure for automotive body applications, such an aluminum bumper extrusion joined to a steel crush box connection. The first part includes a notch for hiding the start and end of the joint. A transition plate formed of a mixture of aluminum material and steel material can be disposed between the first part and the second part to provide the notch. The second part can include a mechanical fastener further joining the parts together. In another embodiment, the second part includes a plurality of dimples and is welded to the first part along the dimples.

Joining of dissimilar materials

A welding tip () for spot welding a first part () formed of conductive metal, for example aluminum, to a second part () formed of aluminum or another conductive metal, such as steel, is provided. The welding tip () includes a notch () at a distal end () and a convex contact surface () extending radially outwardly and upwardly from the notch () for engaging a surface of the first part (). The rotating welding tip () forms a depression () on the surface of the first part () during the welding process. The notch () creates a pin () in the center of the depression () which provides a fixed axis of rotation for the rotating welding tip () and prevents the welding tip () from moving radially relative to the fixed axis, thereby improving the quality of the final spot weld () and reducing process time.

Aluminum spot welding method

A hybrid laser arc welding assembly including a gas metal arc welding torch and a laser arc welding laser head. The torch and laser head are disposed adjacent one another and aimed at targets of a pair of work pieces spaced from one another such that the melted material produced by the torch overlaps with the melted material produced by the laser head, and therefore, the torch and laser head combine to create a hybrid laser arc weld to join the work pieces. The laser head is adjustable dynamically relative to the work-pieces to optimize the hybrid laser arc weld.

Laser welding assembly and method

A spot welding tip for use in a spot welding machine includes a base portion having a longitudinal base axis that passes through a center of the base portion. A tip portion extends from the base portion and provides a contact surface. The tip portion includes a longitudinal tip axis that passes through a center of the tip portion and a center of the contact surface. The spot welding tip includes a transverse axis that is perpendicular to both the base axis and the tip axis. The base axis and the tip axis are parallel to one another and offset from one another by a length. The contact surface is angled with respect to the transverse axis by an angle.

Spot welding tip for a spot welding machine

A method of manufacturing a vehicle structure including a laser welded fastener includes positioning a first panel in engagement with a second panel to provide access to the first panel by a laser beam. The first panel is laser welded to the second panel. A fastener including projections axially extending from a first surface of a flange are formed. The projections are engaged with a surface of the first panel to space apart the first surface of the flange from the surface of the first panel. Laser welding is initiated by directing a laser beam toward one of the flange of the fastener and the first panel. Gas is vented from an area between the first surface of the flange and the surface of the first panel. The flange is laser welded to the first panel.

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Shelby Township, MI, United States of America

John Edward Hill