公开(公告)号：US20040056001A1

公开(公告)日：2004-03-25

申请号：US10253099

申请日：2002-09-24

Applicant: DELPHI TECHNOLOGIES INC.

Inventor： Venkatasubramanian Ananthanarayanan ,  Desra N. Herbst ,  Dharmendra M. Ramachandra

IPC: B23K011/00

CPC classification number: B23K33/00 ,  B23K11/0935 ,  B23K11/3009 ,  B23K11/3081

Abstract: 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.

Abstract translation: 具有由金属板，管和类似形状形成的第一和第二构件的焊接结构通过使用用于将第二构件连接到具有从其延伸的折叠边缘的第一构件的方法而经济地制造。 折叠的边缘限定折叠边缘内的气隙。 第一和第二构件通过在足够的压力下将折叠的边缘压靠第二构件连接在一起，以使折叠的边缘平坦化，使得折叠边缘内部基本上不存在气隙，并且将第一和第二构件的电阻焊接在一起。 第二构件和边缘分别限定其搭接表面。 折叠边缘内的气隙大体上平行于配合面延伸。 轮缘和第二构件的拼接表面通过在大体上垂直于拼接表面的方向上通过折叠边缘施加压力而相互强迫。 在施加压力的同时，第一级电流可以通过第一和第二构件，用于通过电阻加热来软化边缘，并使软化的边缘相对于第二构件变形。 保持压力，并且施加高于第一电流电流的第二电平电流足以至少部分地熔化折叠边缘并在第一和第二构件之间形成变形阻力焊缝的时间。