Abstract:
A method of spot welding a workpiece stack-up that includes a steel workpiece and an adjacent aluminum alloy workpiece involves passing an electrical current through the workpieces and between opposed welding electrodes. The formation of a weld joint between the adjacent steel and aluminum alloy workpieces is aided by a cover plate that is located between the aluminum alloy workpiece that lies adjacent to the steel workpiece and the welding electrode disposed on the same side of the workpiece stack-up. The cover plate, which includes an intruding feature, affects the flow pattern and density of the electrical current that passes through the adjacent steel and aluminum alloy workpieces in a way that helps improve the strength of the weld joint.
Abstract:
A method of spot welding a workpiece stack-up that includes a steel workpiece and an adjacent aluminum alloy workpiece involves passing an electrical current through the workpiece stack-up and between facially aligned welding electrodes in contact with opposed sides of the stack-up. The formation of a weld joint between the adjacent steel and aluminum alloy workpieces is aided by an intruding feature located in an aluminum alloy workpiece that provides and delineates one side of the workpiece stack-up and against which a welding electrode is pressed over the intruding feature at the weld site. The intruding feature affects the flow pattern and density of the electrical current that passes through the overlapping workpieces and is also believed to help minimize the effects of any refractory surface oxide layer(s) that may be present on the aluminum alloy workpiece that lies adjacent to the steel workpiece.
Abstract:
Disclosed are self-adjusting wires, methods of making these self-adjusting wires, and thermal joining processes (such as gas metal arc welding or laser brazing) and other processes using these self-adjusting wires. The wires have a core of a metal or metal alloy suitable as a joining material in the joining process and an exterior layer of a shape-memory alloy, which may be continuous about the exterior of the core or discontinuous such as a longitudinal strip or strips. The shape-memory alloy of the self-adjusting wire is “trained” to a straight-wire shape in its austenite phase. In using the self-adjusting wire in a process, a bent end of the self-adjusting wire is straightened by heating the self-adjusting wire above the austenite phase transition temperature of the shape-memory alloy.