Gm Global Technolgoy Operations, Inc.

University of Michigan

Suzuki Motor Corporation

Jilin University

Other

Tianjin University

Pei-chung Wang

Robin Stevenson

Bradley J Blaski

James Franklin Hengel

Peter C Sun

Steven Cipriano

John D Fickes

Richard Clemence Janis

Spyros Pete Mellas

Susan M Smyth

Zhenke Teng

Michael J Karagoulis

Phillip M Turner

James W Wells

Hai-Lung Tsai

Zhongxia Liu

Kenneth R Schmidt

Yueh-Se J Huang

Roland J Menassa

John Patrick Spicer

Ningjian Huang

Shixin Jack Hu

Daniel B Hayden

Wenkao Hou

Blair E Carlson

Douglas Martin Linn

Jorge F Arinez

Miguel Arturo Saez

Guoxian Xiao

Mark O Vann

Jason M Brown

David P Kelly

Paul M Zardus

Robert T Thornton

Wayne Cai

Dalong Gao

Chen-Shih Wang

Louis G Hector, Jr

Debejyo Chakraborty

Charles Weldon Wampler, Ii

Samuel Paul Marin

Xinmin Lai

Joseph Clifford Simmer

Guanlong Chen

Mark D Gugel

Joseph James Speranza

Anthony V Minatel

Yansong Zhang

Robert J Gollehur

Xihua Zhao

James Michael Ward

Hamid Ghavami Kia

David R Sigler

Sanjeev Manubhai Naik

William C Lin

Richard J Skurkis

Charles W Wampler, Ii

Yongqiang Li

Man-Feng Chang

Balarama Vempaty Murty

Jeffrey A Abell

James C O'Kane

Ingrid A Rousseau

Xiaohong Gayden

Mark A Voss

Charles J Bruggemann

Bhavesh Shah

Sanjay Mahasukhlal Shah

Hesham Ahmed Ezzat

Joseph M Lendway, Iv

Dooil Hwang

Chih-chang Chen

Wuhua Yang

Timothy J Roggenkamp

Daniel C Hutchinson

Jessica A Schroeder

Michael G Poss

Doru N Serban

Diana Marie Wegner

Ashish S Krupadanam

Neil David McKay

Saul S Lee

Shuxin Wang

Houng Yue Chang

Masami Takeshi

Toshinori Sakai

Alexander Michael Turley

Donn W Glander

Athreya Nagesh

Lei Zhao

Kaushik Arjunan Iyer

Thomas R Jones

Robert W Watson

Narayanan P Menon

Zongqing Lin

Edward J Grant

Hao Du

Tommy Christensen

Ugur Ersoy

Kon-Mei Ewing

Methods for resistance welding, resistance-welded assemblies, and vehicles including resistance-welded assemblies are provided. An exemplary resistance welding method includes compressing a workpiece stack-up with an interface material between first and second workpieces to squeeze a portion of the interface material to a reduced thickness. After compressing the workpiece stack-up, the first welding electrode contacts the first workpiece at an operating contact area between the first welding electrode and the first workpiece that is greater than an initial contact area. The method also includes passing an electrical current between the welding electrodes to form a molten weld pool within the workpieces, and ceasing the passing of the electrical current between the welding electrodes to allow the molten weld pool to solidify into a weld nugget that forms all or part of a weld joint between the workpieces.

Resistance-welded assemblies and resistance welding methods

Welding electrodes, methods, and vehicles are provided. The welding electrodes include a body that includes a weld face on a distal end of the body configured to contact a workpiece and apply an electrical current thereto. The body has a maximum diameter of 13 millimeters or less. The welding electrode includes an insulative material covering at least a portion of the body, the insulative material configured to mitigate current shunting upon contact between the insulative material and a workpiece of a workpiece stack-up while using the welding electrode to resistance weld the workpiece stack-up.

Resistance welding electrodes, methods of welding flanges therewith, and vehicles

Methods and systems for joining multiple workpieces are provided. In one example, the method includes dispensing adhesive on a first workpiece. A second workpiece is contacted with the adhesive such that the adhesive is disposed between the first and second workpieces. Resistance heating is produced in the first and second workpieces at first processing conditions to partially cure the adhesive and affix the first and second workpieces together to form a partially cured, adhesive-joined workpiece assembly. The partially cured, adhesive-joined workpiece assembly is exposed to heat at second processing conditions to substantially fully cure the adhesive.

Method and system for joining workpieces

Systems, methods, and apparatuses of a welding system are disclosed and include a first stage of a scanning device for scanning weld parts to generate a three-dimensional (3D) profile of a weld target wherein the 3D profile captures matching imperfections of a meeting together of the set of weld parts when performing the weld operation; and the second stage of a monitoring device to monitor the weld operation and to generate a data of high-resolution measurements of the weld operation; wherein the first stage further includes the monitoring device determining a weld schedule based on the 3D profile, and to adjust the weld schedule while the weld operation progresses to adapt to predicted distortion based on the 3D profile and to sensed distortion; wherein the second stage further includes a plurality of sensors to sense a set of components associated with the weld operation to generate high-resolution data of measurements.

Systems, methods, and apparatuses, of an arc welding (AW) process and quality monitoring

A method for tempering steel for riveting includes positioning a first component having a first composition over a second component having a second composition, and resistance spot welding the first component to the second component using a resistance spot weld gun to form a spot weld. The method includes tempering at least one of the first component, the second component and the spot weld with the resistance spot weld gun, and coupling a third component having a third composition to the first component and the second component with a rivet, and the third composition is different than the first composition and the second composition.

Methods for tempering of steel for riveting

A fastening assembly includes a panel defining an aperture, a fastener having a head, a shaft portion extending from the head, and a recess formed in the head, and a sacrificial primary anode insert disposed in the recess. The sacrificial primary anode insert is configured to corrode at a rate faster than a corrosion rate of the fastener.

Fastening assembly

Methods for ultrasonic welding of thermoplastic polymer workpieces and assemblies made therefrom are provided. The method may comprise disposing a first region of a first thermoplastic polymer workpiece and a second region of a second thermoplastic polymer workpiece between an ultrasonic horn and an anvil of an ultrasonic welding device. The first workpiece has a preformed deformation and at least one of the first and/or second workpieces has an adhesive precursor applied thereto. The ultrasonic horn or anvil seats within the preformed deformation. Ultrasonic energy is applied from the ultrasonic horn to create a weld nugget between the first and second workpieces. The assembly thus formed has a green strength sufficient to be further processed immediately. The methods provide a robust weld joint with controlled adhesive bondline thickness.

Ultrasonic weld-bonding of thermoplastic composites

A weld system includes: a robot control module configured to actuate a robot and move a welder along a joint of metal workpieces during welding, the welder being attached to the robot; a weld control module configured to, during the welding, apply power to the welder, supply a shield gas, and supply electrode material; a vision sensor configured to, during the welding, optically measure distances between the vision sensor and locations, respectively, on an outer surface of a weld bead created along the joint by the welder; and a weld module configured to: determine a strength of the weld bead at a location based on: the distances at the location along the joint; and at least one parameter from at least one of the robot control module during the welding, the weld control module during the welding, and a sensor configured to capture data of the welding during the welding.

Real-time weld quality analysis systems and methods

A method of joining a multiple member work-piece includes providing a first steel work-piece having a first thickness and a second steel work-piece having a second thickness. The first thickness is at least twice the second thickness. A third material is disposed in contact with the second steel work-piece. For example, the third material may be in the form of a rivet, a plurality of pins, or a coating material. The method includes resistance welding the first and second work-pieces together. A bonded assembly includes the first and second steel members and the third material being bonded together, where the thickness of the first member is at least twice the thickness of the second member.

Method of joining steel work-pieces having different gauge ratios

A method of forming an assembly includes providing a metallic first workpiece having base and a first layer disposed on the base and adhering a second layer onto the first layer. One of the first and second layers is formed of a zinc-based material formed of at least a majority of zinc, and the other of the first and second layers is formed of a metallic alloying material having a melting point higher than the melting point of the zinc-based material. Preferably, the first layer is formed of the zinc-based material, and the second layer is formed of the metallic alloying material with the higher melting point. A metallic second workpiece is disposed in contact with the second layer. A welding operation is performed to join the first workpiece to the second workpiece. A welded assembly is also provided.

Pretreatment of weld flanges to mitigate liquid metal embrittlement cracking in resistance welding of galvanized steels

A riveting system, for use in mechanically linking adjacent workpieces, including a rivet having a height greater than a sum of thicknesses, measured along a line of riveting, of the workpieces being linked, so that the rivet can pass fully through the workpieces. The system also includes a riveting die, which may be a separate product. The die includes a protrusion extending from a peak toward a transition point; and a trough having a trough surface. The trough surface includes a trough inner wall, extending from the transition point to a trough bottom, and a trough outer wall, extending from the trough bottom to a trough outer edge. The technology also includes computerized systems for comparing a load-displacement profile of riveting to a pre-set profile to determine whether the riveting was performed properly.

Systems and methods for joining components by riveting

A system and method of enhanced automated welding of a first workpiece and a second workpiece are provided. The method comprises providing a system for intelligent robot-based welding of the first workpiece and the second workpiece. The method further comprises determining a geometrical location of the first workpiece and the second workpiece to be welded at a welding sequence based a predetermined process variable. The method further comprises adjusting the predetermined process variable based on the geometrical location of the first and second workpieces to define an actual process variable. The method further comprises welding a first portion of the first and second workpieces with the actual process variable to define a first welded portion. The method further comprises determining a weld quality of the first welded portion.

System and method of enhanced automated welding of first and second workpieces

A high temperature substrate coating to mitigate liquid metal embrittlement (LME) cracking in automobile vehicles includes a substrate. A coating is disposed on the substrate, the coating being one of a zinc-based material and an aluminum-based material, with the coating having a melting point of at least 500&#xb0; C.

High temperature coatings to mitigate weld cracking in resistance welding

A method of joining a multiple member work-piece includes providing a first steel work-piece having a first electrical resistivity and a second steel work-piece having a second electrical resistivity that is lower than the first electrical resistivity. A third material is disposed in contact with the second steel work-piece. The third material has an electrical resistivity that is greater than the second electrical resistivity. The method includes resistance welding the first and second work-pieces together. The third material may be in the form of a rivet, a third work-piece, or a coating material disposed between the first and second work-pieces. A bonded assembly includes steel members and a third material being bonded together, wherein the electrical resistivity of the second member is lower than the electrical resistivity of the first member, and the third material has an electrical resistivity that is greater than the electrical resistivity of the second member.

Method of joining steel having different resistivities

A method of resistance spot brazing a workpiece stack-up that includes a first thin-gauge steel workpiece and a second thin-gauge steel workpiece. The method includes several steps. A first step involves applying a filler material to a surface of the first thin-gauge steel workpiece. A second step involves bringing a surface of the second thin-gauge steel workpiece to adjoin the filler material. A third step involves clamping a first welding electrode and a second welding electrode on the first and second thin-gauge steel workpieces and over the filler material. A fourth step involves passing electrical current between the first and second welding electrodes and hence through the filler material. And a fifth step involves terminating passage of the electrical current in order to establish a brazed joint between the first and second thin-gauge steel workpieces.

Resistance spot brazing workpiece stack-ups having one or more thin-gauge steel workpieces

Growing community of inventors

Troy, MI, United States of America

Pei-chung Wang