公开(公告)号：US10577710B2

公开(公告)日：2020-03-03

申请号：US15804948

申请日：2017-11-06

Applicant: GM Global Technology Operations LLC

Inventor： Surender Maddela ,  Blair E. Carlson

IPC: C25D13/22 ,  C25D13/12 ,  C09D5/44 ,  C25D13/02 ,  C25D13/04 ,  C25D13/20

Abstract: A method for forming an adhesion promoting layer and a corrosion resistant layer over the surfaces of a body-in-white (“BIW”) structure is provided. The method includes immersing the BIW structure in a pre-activating bath to pre-activate the surfaces of the BIW structure. The surfaces of the BIW structure comprise at least an aluminum alloy surface, at least a surface comprising ferrous metal, zinc, or TiZr, and the surfaces are substantially free of magnesium alloys. An adhesion promoting layer comprising cerium and a corrosion resistant layer comprising polymers are subsequently deposited over the pre-activated surfaces of the BIW structure by immersing the BIW structure in an aqueous bath comprising a source of cerium cations and a polymer precursor.

公开(公告)号：US10456856B2

公开(公告)日：2019-10-29

申请号：US15418768

申请日：2017-01-29

Applicant: GM Global Technology Operations LLC

Inventor： David R. Sigler ,  Blair E. Carlson ,  Michael J. Karagoulis

IPC: B23C3/12 ,  B23K11/30 ,  B23B5/16

Abstract: A cutting tool that can simultaneously cut and restore asymmetric weld face geometries of two welding electrodes that are subject to different degradation mechanisms is disclosed along with a method of using such a cutting tool during resistance spot welding of workpiece stack-ups that include dissimilar metal workpieces. The cutting tool includes a first cutting socket and a second cutting socket. The first cutting socket is defined by one or more first shearing surfaces and the second cutting is defined by one or more second shearing surfaces. The first shearing surface(s) and the second shearing surface(s) are profiled to cut and restore a first weld face geometry and a second weld face geometry, respectively, that are different from each other upon receipt of electrode weld faces within the cutting sockets and rotation of the cutting tool.

公开(公告)号：US20190134735A1

公开(公告)日：2019-05-09

申请号：US15807219

申请日：2017-11-08

Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC

Inventor： Amberlee S. Haselhuhn ,  David R. Sigler ,  Blair E. Carlson

IPC: B23K11/11 ,  B23K11/30 ,  B23K35/02 ,  B23B5/16 ,  B32B15/01

Abstract: A welding electrode and a method of using the welding electrode for resistance spot welding are disclosed. The welding electrode includes a body and a weld face. The weld face includes a central dome portion and a shoulder portion that surrounds the central dome portion and extends from an outer circumference of the weld face upwardly and radially inwardly to the central dome portion. The central dome portion has a series of radially-spaced ringed ridges that project outwardly from a base dome face surface. The series of radially-spaced ringed ridges on the central dome portion includes an innermost ringed ridge and an outermost ringed ridge. The outermost ringed ridge on the central dome portion has a radial inner side surface and a radial outer side surface. The radial outer side surface extends below the base dome face surface down to the shoulder portion of the weld face.

公开(公告)号：US10189227B2

公开(公告)日：2019-01-29

申请号：US15252878

申请日：2016-08-31

Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC

Inventor： Anil K. Sachdev ,  Raja K. Mishra ,  Jon T. Carter ,  Tyson W. Brown ,  Blair E. Carlson ,  David R. Sigler ,  Robert N. Saje ,  Matthew P. Simonin

IPC: B21D26/021 ,  B32B7/02 ,  B32B7/04 ,  B32B15/04 ,  B32B15/18 ,  B32B15/20 ,  B32B27/32 ,  B21D35/00 ,  B60R13/02 ,  B32B37/00

Abstract: A panel assembly is formed by a plurality of bonds between two sheet materials in a face to face relationship to form a preform. The plurality of bonds define a closed perimeter region between the two sheet materials and an open perimeter region between the two sheet materials. The preform may be formed into a predefined shape. Pressurized fluid is applied through an inlet into the open perimeter region to expand the preform. The pressurized fluid expands the open perimeter region such that the two sheet materials expand in an opposing direction, thereby defining an expanded open perimeter region. The closed perimeter region between the two sheet materials remains vacant of the pressurized fluid such that the closed perimeter region is not expanded. The expanded open perimeter region is filled with a filler material for improving a performance characteristic of the panel assembly, e.g., strength, sound absorption, or stiffness.

公开(公告)号：US20180257166A1

公开(公告)日：2018-09-13

申请号：US15976163

申请日：2018-05-10

Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC

Inventor： David R. Sigler ,  Blair E. Carlson ,  Yelena Myasnikova ,  Michael J. Karagoulis

IPC: B23K11/20 ,  B23K11/11 ,  B23K103/20

CPC classification number: B23K11/20 ,  B23K11/115 ,  B23K2103/20

Abstract: A workpiece stack-up that includes at least a steel workpiece and an aluminum-based workpiece can be resistance spot welded by employing a multi-stage spot welding method in which the passage of electrical current is controlled to perform multiple stages of weld joint development.

公开(公告)号：US20180117716A1

公开(公告)日：2018-05-03

申请号：US15340651

申请日：2016-11-01

Applicant: GM Global Technology Operations LLC

Inventor： Xin Yang ,  Blair E. Carlson ,  Yongbing Li

IPC: B23K35/365 ,  B23K1/20 ,  B23K35/02

CPC classification number: B23K35/365 ,  B23K1/203 ,  B23K35/025

Abstract: The present disclosure relates a bonding system formed by a process that provides a first substrate and a second substrate. A flux coating is applied to the first contact surface, and a solder-adhesive mixture comprising an adhesive and a plurality of solder elements in at least a portion of the adhesive is applied to the first contact surface. The second substrate is positioned adjacent the solder-adhesive mixture much that a second contact surface of the second surface is opposite the first contact surface, and heat is applied to the solder-adhesive mixture by way of at least one of the first and second contact surfaces. The solder-adhesive mixture is heated to a temperature that is intended to at least partially melt or at least partially vaporize the flux coating upon contact to promote a bonding condition between the solder-adhesive mixture and the first substrate.

公开(公告)号：US20180117694A1

公开(公告)日：2018-05-03

申请号：US15340608

申请日：2016-11-01

Applicant: GM Global Technology Operations LLC

Inventor： Xin Yang ,  Blair E. Carlson ,  Yongbing Li

IPC: B23K1/20 ,  B23K1/19

CPC classification number: B23K1/203 ,  B23K3/0623

Abstract: The present disclosure relates a bonding system formed by a process that provides a first substrate and a second substrate. A flux coating is applied to the first contact surface, and a solder-adhesive mixture comprising an adhesive and a plurality of solder elements in at least a portion of the adhesive is applied to the first contact surface. The solder-adhesive mixture is heated to at least partially melt or at least partially vaporize the flux coating to promote a bonding condition between the solder-adhesive mixture and the first substrate. Finally, the second contact surface is then positioned adjacent the solder-adhesive mixture. The present technology additionally includes methods to produce a solder-reinforced adhesive bond joining a first substrate and a second substrate.

公开(公告)号：US20170297136A1

公开(公告)日：2017-10-19

申请号：US15485996

申请日：2017-04-12

Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC

Inventor： Tyson W. Brown ,  David R. Sigler ,  Blair E. Carlson ,  Amberlee S. Haselhuhn

IPC: B23K11/20 ,  C22C38/04 ,  C22C38/02 ,  B23K35/36 ,  B23K11/18 ,  B23K11/11 ,  B23K35/30 ,  B23K35/02 ,  B23K35/00 ,  C22C38/16 ,  B23K103/20 ,  B23K103/04 ,  B23K103/10

CPC classification number: B23K11/20 ,  B23K11/115 ,  B23K11/163 ,  B23K11/185 ,  B23K35/002 ,  B23K35/004 ,  B23K35/0294 ,  B23K35/3053 ,  B23K35/3612 ,  B23K2101/006 ,  B23K2101/18 ,  B23K2101/34 ,  B23K2101/35 ,  B23K2103/04 ,  B23K2103/10 ,  B23K2103/20 ,  C22C38/02 ,  C22C38/04 ,  C22C38/16

Abstract: A method of resistance spot welding a workpiece stack-up that includes an aluminum workpiece and an overlapping adjacent steel workpiece so as to minimize the thickness of an intermetallic layer comprising Fe—Al intermetallic compounds involves providing reaction-slowing elements at the faying interface of the aluminum and steel workpieces. The reaction-slowing elements may include at least one of carbon, copper, silicon, nickel, manganese, cobalt, or chromium. Various ways are available for making the one or more reaction-slowing elements available at the faying interface of the aluminum and steel workpieces including being dissolved in a high strength steel or being present in an interlayer that may take on a variety of forms including a rigid shim, a flexible foil, a deposited layer adhered to and metallurgically bonded with a faying surface of the steel workpiece, or an interadjacent organic material layer that includes particles containing the reaction-slowing elements.

公开(公告)号：US20170282303A1

公开(公告)日：2017-10-05

申请号：US15470062

申请日：2017-03-27

Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC

Inventor： Hui-Ping Wang ,  David R. Sigler ,  Blair E. Carlson

IPC: B23K35/02 ,  B23K11/20 ,  B23K11/18 ,  B23K11/30 ,  B23K11/11

CPC classification number: B23K35/0255 ,  B23K11/0026 ,  B23K11/115 ,  B23K11/185 ,  B23K11/20 ,  B23K11/30 ,  B23K11/3009 ,  B23K11/3018 ,  B23K35/02 ,  B23K2101/006 ,  B23K2103/20

Abstract: A radially slotted welding electrode is disclosed that may be used in conjunction with a companion second welding electrode to conduct resistance spot welding on a workpiece stack-up assembly that includes a steel workpiece and an overlapping adjacent aluminum workpiece, especially when an intermediate organic material layer is disposed between the workpiece faying surfaces of the steel and aluminum workpieces. The radially slotted welding electrode includes a weld face that has a central upstanding plateau and a convex dome portion that surrounds the central upstanding plateau and which includes a plurality of circumferentially spaced trapezoidal weld face sections that include transverse upstanding arcuate ridges. Together, the central upstanding plateau and the trapezoidal weld face sections of the convex dome portion define an annular channel that surrounds the central plateau and a plurality of radial slots that communicate with and extend outwards from the central channel.

公开(公告)号：US20170225263A1

公开(公告)日：2017-08-10

申请号：US15418771

申请日：2017-01-29

Applicant: GM Global Technology Operations LLC

Inventor： David R. Sigler ,  Blair E. Carlson ,  Michael J. Karagoulis ,  James G. Schroth

IPC: B23K11/30 ,  B23B5/16

CPC classification number: B23K11/3063 ,  B23B5/166 ,  B23K11/20

Abstract: A cutting tool that can simultaneously cut and restore asymmetric weld face geometries of two welding electrodes that are subject to different degradation mechanisms is disclosed along with a method of using such a cutting tool during resistance spot welding of workpiece stack-ups that include dissimilar metal workpieces. The cutting tool includes a first cutting socket and a second cutting socket. The first cutting socket is defined by one or more first shearing surfaces and the second cutting is defined by one or more second shearing surfaces. The first shearing surface(s) and the second shearing surface(s) are profiled to cut and restore a first weld face geometry and a second weld face geometry, respectively, that are different from each other upon receipt of electrode weld faces within the cutting sockets and rotation of the cutting tool.