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Небесная энциклопедия

Космические корабли и станции, автоматические КА и методы их проектирования, бортовые комплексы управления, системы и средства жизнеобеспечения, особенности технологии производства ракетно-космических систем

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Мониторинг СМИ

Мониторинг СМИ и социальных сетей. Сканирование интернета, новостных сайтов, специализированных контентных площадок на базе мессенджеров. Гибкие настройки фильтров и первоначальных источников.

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Поддерживает ввод нескольких поисковых фраз (по одной на строку). При поиске обеспечивает поддержку морфологии русского и английского языка
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Применить Всего найдено 155. Отображено 100.
12-04-2012 дата публикации

BIMETALLIC FORGING AND METHOD

Номер: US20120088116A1
Автор: Carlson Blair E., Krajewski Paul E.
Принадлежит: GM GLOBAL TECHNOLOGY OPERATIONS, INC.

A method of forming a bimetallic forging includes providing a blank comprising at least a first element and a second element of a first metal, and an insert of a second metal. A blank is configured such that the insert may be substantially encapsulated by a shell defined by the first element and the second element. The blank is forged to form a bimetallic forging including an outer portion defined by the shell, an inner portion defined by the insert, and an interface layer therebetween. In a non-limiting example, the first metal is substantially comprised of aluminum and the second metal is substantially comprised of magnesium. In a non-limiting example, the blank may be forged to form a vehicle wheel including an aluminum skin substantially encapsulating a magnesium inner portion, providing wheel with a high strength to weight ratio and improved corrosion performance. 1. A method of forming a bimetallic forging , the method comprising:providing a first element substantially made of a first metal;providing a second element substantially made of the first metal;providing an insert substantially made of a second metal;forming a blank comprised of the first element, the second element, and the insert;wherein the blank is configured such that the insert is substantially encapsulated by a shell defined by the first element and the second element; andforging the blank to form the forging.2. The method of claim 1 , wherein forging the blank to form the forging further comprises forming a forging including:an outer portion defined by the shell;an inner portion defined by the insert; andan interface layer formed between the inner portion and the outer portion.3. The method of claim 1 , further comprising operatively joining the first element and the second element.4. The method of claim 1 ,wherein the first metal is one of aluminum and an aluminum alloy; andwherein the second metal is one of magnesium and a magnesium alloy.5. The method of claim 1 , further comprising: ...

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Номер записи: 1
02-08-2012 дата публикации

CRACK AVOIDANCE IN RESISTANCE SPOT WELDED MATERIALS

Номер: US20120193331A1
Автор: Carlson Blair E., Wang Pei-Chung, Yang David S.
Принадлежит: GM GLOBAL TECHNOLOGY OPERATIONS LLC

Methods of crack avoidance during resistance spot welding are provided. The compressive stress from the spot welding is distributed across an electrode assembly having an enlarged footprint. The electrode assembly includes a conductive core and a non-conductive cover. The delivery of current through the electrode assembly is localized to the conductive core. 1. A method of preventing crack formation in resistance spot welded materials comprising:covering at least two edges of an electrode with a non-conductive material to provide an electrode assembly having a discontinuous non-conductive cover about a periphery of the electrode; andwelding a first metal sheet to a second metal sheet with the electrode assembly.2. The method of claim 1 , further comprising creating at least one spot weld.3. The method of claim 2 , further comprising distributing a compressive force over a contact surface of the electrode assembly.4. The method of claim 1 , further comprising removably covering the region of the electrode with the non-conductive material to provide the electrode assembly.5. The method of claim 1 , wherein the non-conductive material defines an opening through which to expose the electrode.6. The method of claim 1 , further comprising securing the non-conductive material to the electrode.7. The method of claim 6 , wherein the securing of the non-conductive material to the composite electrode comprises a technique selected from the group consisting of mechanical securing claim 6 , using an adhesive claim 6 , and combinations thereof.8. The method of claim 7 , further comprising forming at least one spot weld that is substantially free from surface cracks.10. The method of claim 1 , wherein at least one of the first metal sheet and the second metal sheet is made of a zinc-coated steel.11. A method of reducing crack formation in resistance spot welded materials comprising:covering a region of an electrode with a non-conductive ceramic material to provide an electrode ...

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Номер записи: 2
16-08-2012 дата публикации

METHOD OF JOINING BY ROLLER HEMMING AND SOLID STATE WELDING AND SYSTEM FOR SAME

Номер: US20120204412A1
Автор: Carlson Blair E., Carsley John E., Schroth James G., Sigler David R.
Принадлежит: GM GLOBAL TECHNOLOGY OPERATIONS LLC

A method of joining a first and a second work piece, such as automotive closure panels, includes supporting the work pieces on a fixture, and then joining the work pieces to one another by a first solid state weld with a vibrating roller head of a tool assembly, such as a robotically-controlled ultrasonic seam welder. Next, a flange of the second work piece is hemmed about an outer periphery of the first work piece using the same or a different roller head with the work pieces supported by the fixture. The hemmed flange is then joined to the first work piece by a second solid state weld with the vibrating roller head of the robotically-controlled ultrasonic seam welder. A system for joining a first and a second work piece is also provided. 1. A method of joining a first work piece to a second work piece comprising:supporting the work pieces on a fixture;joining the work pieces to one another by a first solid state weld with a vibrating roller head of a robotically-controlled ultrasonic welder;hemming a flange of the second work piece about an outer periphery of the first work piece using the same or a different roller head with the work pieces supported by the fixture; andjoining the hemmed flange to the first work piece panel by a second solid state weld with the vibrating roller head of the robotically-controlled ultrasonic welder.2. The method of claim 1 , wherein the joining the work pieces to one another by a first solid state weld includes:moving one of the roller head and the fixture so that the roller head moves along a predefined path on the work pieces while providing a normal force to the work pieces through the roller head; andvibrating the roller head during said moving to create the first solid state weld of the work pieces.3. The method of claim 1 , wherein the joining the hemmed flange to the first work piece by the second solid state weld includes:moving one of the roller head and the fixture so that the roller head moves along at least a portion of ...

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Номер записи: 3
13-09-2012 дата публикации

WELDING APPARATUS FOR INDUCTION MOTOR AND METHOD OF WELDING INDUCTION MOTOR

Номер: US20120228272A1
Автор: Agapiou John S., Carlson Blair E., Kleber Richard M., Sigler David R., Szymanski Robert T.
Принадлежит: GM GLOBAL TECHNOLOGY OPERATIONS LLC

A welding apparatus for an induction motor includes a fixture operable to support a rotor and rotate the rotor about an axis of rotation of the motor, and a welding head supported adjacent the fixture and operable to weld conductor bars located about the surface of the rotor to the first shorting ring when the fixture supports the rotor. A controller controls the fixture to selectively rotate the rotor. The controller moves the welding head, the fixture, or both, so that the welding head is in a welding position, and causes the welding head to weld the conductor bars to the first shorting ring while remaining in the welding position, with the rotor rotating to create a substantially circular weld path along the first shorting ring. In some embodiments, the conductor bars are welded to both shorting rings simultaneously. A method of welding an induction motor is also provided. 1. A welding apparatus for an induction motor; wherein the induction motor has an annular rotor defining an axis of rotation , conductor bars spaced about an outer surface of the annular rotor , and first and second shorting rings connected at first and second ends of the annular rotor , the apparatus comprising:a fixture operable to support the rotor and rotate the rotor about the axis of rotation;a welding head supported adjacent the fixture and operable to weld the conductor bars to the first shorting ring when the fixture supports the rotor;at least one controller operable to control the fixture to selectively rotate the rotor; wherein the at least one controller is operable to move at least one of the welding head and the fixture so that the welding head is in a welding position and to cause the welding head to weld the conductor bars to the first shorting ring while remaining in the welding position with the rotor rotating to create a substantially circular weld path along the first shorting ring.2. The welding apparatus of claim 1 , wherein the welding head is a first welding head and ...

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Номер записи: 4
29-11-2012 дата публикации

CONSUMABLE TOOL FRICTION STIR PROCESSING OF METAL SURFACES

Номер: US20120301603A1
Автор: Carlson Blair E., Song Guangling
Принадлежит: GM GLOBAL TECHNOLOGY OPERATIONS LLC

The surface composition of a metal article may be modified by depositing a coating layer material of a different composition from a consumable tool which is urged against the article surface while being rotated about an axis generally normal to the surface. The frictional heating resulting from rotation of the tool under applied pressure increases the temperature of the article-contacting portion of the tool so that it adheres to and bonds to the magnesium alloy article. In an embodiment the tool material is selected to be more corrosion-resisting than or sacrificial to the substrate metal alloy. In another embodiment the tool material is selected to react with the magnesium surface to form a more corrosion-resistant coating or a sacrificial layer. In another embodiment a holemaking cutting tool may be incorporated in to the consumable tool to enable fabrication of a hole with a surrounding, more corrosion-resistant annular surface. Further processing of the article with its coating layer may include: buffing, burnishing, or polishing the layer; and heat treatment to promote diffusion of the layer composition into the article composition. 1. A method of enhancing the corrosion-resistance of a metal alloy article by depositing a corrosion-resisting metal coating layer over at least a portion of a surface of the article , the method comprising:rotating a tool of a corrosion-resisting material for application to the surface of the metal alloy article while applying a force to press the tool against the surface of the article; andthereby transferring material from the tool to the surface of the article to deposit on the surface of the article an adherent, corrosion-resisting coating layer.2. The method of enhancing the corrosion-resistance of the metal alloy article of claim 1 , in which the tool is generally cylindrical with two ends claim 1 , and having a cylinder axis claim 1 , and the tool is rotated about its cylindrical axis while one end is pressed against the ...

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Номер записи: 5
20-12-2012 дата публикации

Method and apparatus for joining multiple components

Номер: US20120317786A1
Автор: Blair E. Carlson, David Yang, Jeff Wang, Pei-Chung Wang
Принадлежит: GM GLOBAL TECHNOLOGY OPERATIONS LLC

A method of joining multiple components includes stacking the components vertically. Each component includes two opposite substantially planar surfaces that are arranged in a column when the components are stacked. The method also includes placing the stacked components in a clinch-crimping apparatus having a first punch, a second punch, and a crimping element. The method also includes displacing a section of the substantially planar surfaces of the stacked components by driving the first punch in a first direction that is substantially perpendicular to the surfaces. The method additionally includes retracting the first punch from the displaced section and crimping the displaced section by the crimping element to form a crush initiator. The method additionally includes disengaging the crimping element from the crimped, displaced section. Furthermore, the method includes clinching the crimped, displaced section by driving the second punch in a second direction that is opposite to the first direction.

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Номер записи: 6
14-03-2013 дата публикации

Heat pipe waterless resistance welding electrode

Номер: US20130062319A1
Автор: Blair E. Carlson, Pei-Chung Wang
Принадлежит: GM GLOBAL TECHNOLOGY OPERATIONS LLC

An apparatus for resistance welding with a welder includes a heat pipe including a hollow tube and a weld electrode fitted around a portion of the heat pipe. The weld electrode and heat pipe are conductively coupled to conduct heat across an inner surface of the weld electrode.

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Номер записи: 7
28-03-2013 дата публикации

CORROSION RESISTANT MAGNESIUM ARTICLE AND METHOD OF MAKING

Номер: US20130078480A1
Автор: Carlson Blair E., Carter Jon T., Sachdev Anil K., Song Guangling
Принадлежит: GM GLOBAL TECHNOLOGY OPERATIONS LLC

The corrosion resistance of formed and shaped sheet magnesium alloy articles may be improved by applying to the article a substantially crack-and pore-free ductile metal layer on at least selected surfaces and cut or sheared edges. An exemplary ductile metal may be aluminum or its alloys. Two methods of applying such a ductile metal layer are described. One method is suitable for extended areas of the magnesium alloy sheet surface, and is applied prior to stamping the article, while a second method, suitable for cut or sheared edges, is intended for application after the article is fully formed. The incorporation of both methods into conventional sheet metal stamping processes to form the corrosion resistant formed magnesium article is described. 1. A corrosion resistant , magnesium-based alloy article comprising a magnesium alloy body having a surface that is expected to be exposed to a corrosive medium in the use of the article , at least a portion of the surface having a spray coating of particles of a ductile metal , the sprayed coating having been mechanically worked and smoothed to render it impermeable to the corrosive medium.2. The corrosion resistant magnesium alloy article recited in in which the ductile metal coating is preponderantly aluminum or preponderantly zinc.3. The corrosion resistant magnesium article of in which the magnesium alloy article is a stamped sheet article.4. A method of fabricating a corrosion resistant claim 1 , magnesium-base alloy article expected to be exposed to a corrosive medium in the use of the article comprising the steps of:forming, on at least a surface of the magnesium article a substantially crack- and pore-free ductile metal coating suitable for preventing access of an electrolyte to the magnesium alloy article and thereby enhancing the corrosion-resistance of the magnesium alloy article, by:spray coating particles of a ductile metal to form a layer of predetermined thickness of a ductile metal on at least a portion of ...

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Номер записи: 8
02-05-2013 дата публикации

SYSTEM AND METHOD FOR GENERATING A WELDED ASSEMBLY

Номер: US20130105046A1
Автор: Carlson Blair E., Hall Mark T.
Принадлежит: GM GLOBAL TECHNOLOGY OPERATIONS LLC

A method of generating a welded assembly includes providing a work-hardened steel component. The method also includes annealing a region on the work-hardened steel component to impart a local temper to the region such that formability of the region is increased. The method additionally includes forming a projection on the annealed region. Furthermore, the method includes clamping a panel against the projection and joining the panel and the work-hardened steel component at the projection via a welding apparatus to generate the welded assembly. A system for generating a welded assembly employing the disclosed method and a method of generating a reinforced assembly are also disclosed. 1. A method of generating a welded assembly , the method comprising:annealing a region on a work-hardened steel component to impart a local temper to the region such that formability of the region is increased;forming a projection on the annealed region;clamping a panel against the projection; andjoining the panel and the work-hardened steel component at the projection via a welding apparatus to generate the welded assembly.2. The method of claim 1 , wherein the work-hardened steel component is formed from a high-strength low-alloy steel and the panel is formed from mild-steel.3. The method of claim 1 , wherein the work-hardened steel component is a press-hardened structural reinforcement for the panel.4. The method of claim 1 , wherein said joining the panel and the work-hardened steel component is accomplished via electric resistance welding.5. The method of claim 1 , wherein said annealing of the region on the work-hardened steel component is accomplished via a heating element.6. The method of claim 5 , wherein the heating element includes an induction coil.7. The method of claim 1 , wherein the welding apparatus includes a pair of electrodes claim 1 , and wherein said clamping the panel against the projection is accomplished via the pair of electrodes.8. A system for generating a ...

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Номер записи: 9
02-05-2013 дата публикации

STRUCTURAL INTEGRITY WELDED ASSEMBLY

Номер: US20130106123A1
Автор: Carlson Blair E., Cunningham Mark Allan, Szymanski Robert T.
Принадлежит: GM GLOBAL TECHNOLOGY OPERATIONS LLC

A welded assembly characterized by improved structural integrity includes a first component disposed along a first plane. The first component includes first and second substantially parallel surfaces, and also includes a channel arranged on the first surface. The welded assembly also includes a second component disposed along a second plane, wherein the second component includes a leading edge. The leading edge of the second component is inserted into the channel of the first component such that an interface is formed between the first and second components. A weld generated on the second surface joins the first component with the second component at the interface such that the assembly is formed. The subject weld may be a friction-stir type of a weld. The subject welded assembly may be a vehicle bumper support. A method of forming such a welded assembly is also disclosed. 1. A welded assembly , the assembly comprising:a first component disposed along a first plane, wherein the first component includes first and second substantially parallel surfaces, and includes a channel arranged on the first surface;a second component disposed along a second plane, the second component having a leading edge; the leading edge of the second component is inserted into the channel of the first component such that an interface is formed between the first and second components; and', 'a weld generated on the second surface joins the first component with the second component at the interface such that the assembly is formed., 'wherein2. The assembly of claim 1 , wherein the first plane is substantially orthogonal to the second plane.3. The assembly of claim 1 , wherein the weld generated on the second surface is a friction-stir weld.4. The assembly of claim 3 , wherein the friction-stir weld penetrates into the channel without emerging on the first surface.5. The assembly of claim 4 , wherein the first component and the second component each retain a respective material microstructure ...

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Номер записи: 10
20-06-2013 дата публикации

REVERSIBLE ELECTRICAL CONNECTOR AND METHOD

Номер: US20130157104A1
Автор: Carlson Blair E., Ulicny John C., Xie Tao
Принадлежит: GM GLOBAL TECHNOLOGY OPERATIONS LLC

A method of reversibly connecting two substrates includes positioning an electrically conductive adhesive connector including a shape memory polymer (SMP) between the substrates, heating the connector to a temperature higher than the SMP transition temperature, applying a load and cooling the connector below the transition temperature to transform the connector to a conforming shape to form an adhesive bond attaching the substrates and providing an electrical connection therebetween. The method may include disconnecting the connector from the substrates by heating the connector above the SMP transition temperature, which may disrupt the electrical connection between the substrates. The connector may be a battery tab connector configured to connect a battery cell to another battery cell or a terminal. The connector may be releasable from the battery tab such that the battery tab is reusable after removal of the connector. The connector may be multi-layer and generally arcuate in a permanent shape. 1. A method comprising:providing an electrically conductive adhesive connector including a shape memory polymer having a glass transition temperature;providing a first substrate and a second substrate, wherein the first substrate and the second substrate are electrically conductive;positioning the connector adjacent to the first substrate and the second substrate;heating the connector to a temperature higher than the glass transition temperature of the shape memory polymer;applying a load on the connector to transform the connector to a conforming shape while cooling the connector to a temperature lower than the glass transition temperature; forms an adhesive bond between the connector and the first and second substrates to operatively attach the first and second substrates; and', 'provides an electrical connection between the first and second substrates., 'wherein the connector in the conforming shape2. The method of claim 1 , wherein the first substrate is a first battery ...

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Номер записи: 11
03-01-2019 дата публикации

Method and apparatus for resistance spot welding overlapping steel workpieces

Номер: US20190001428A1
Автор: Blair E Carlson, David Yang, QI Lu, Wu Tao
Принадлежит: GM GLOBAL TECHNOLOGY OPERATIONS LLC

A method of resistance spot welding a workpiece stack-up comprising overlapping first and second steel workpieces is disclosed, wherein at least one of the steel workpieces comprises an advanced high-strength steel substrate. The workpiece stack-up is positioned between a pair of opposed first and second welding electrodes. A cover is disposed between at least one of the first steel workpiece and the first welding electrode or the second steel workpiece and the second welding electrode at an intended weld site. The workpiece stack-up is clamped between the first and second welding electrodes at the weld site such that at least one of the weld faces of the first and second welding electrodes presses against the cover. The first and second steel workpieces are welded together by passing an electrical current between the first and second welding electrodes at the weld site.

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Номер записи: 12
12-01-2017 дата публикации

COOLING TO CONTROL THERMAL STRESS AND SOLIDIFICATION FOR WELDING OF DISSIMILAR MATERIALS

Номер: US20170008118A1
Автор: Carlson Blair E., Sigler David R., Yang David
Принадлежит:

A workpiece stack-up that includes at least a steel workpiece and an aluminum-based workpiece can be resistance spot welded by a spot welding method in which the welding current is controlled to perform one or more stages of weld joint development. When it is desired to terminate weld current flow and to solidify a liquid weld pool into a weld nugget (of mostly aluminum-based composition), additional cooling is applied to the outer surface of the aluminum-based workpiece around the contact area of the spot welding electrode engaging the surface of the aluminum-based workpiece surface. The additional cooling is applied and controlled so as to increase the rate of solidification of the liquid aluminum-based material and to control the direction of solidification of the weld nugget to better confine impurities, and the like, originally in the melt, at the surface of the steel workpiece. 1. A method of resistance spot welding a workpiece stack-up , which includes an aluminum-based workpiece and a steel workpiece so as to form a resistance spot weld between the aluminum-based workpiece and the steel workpiece , the method comprising:contacting a workpiece stack-up with a pair of spot welding electrodes such that the spot welding electrodes make contact with opposed sides of the workpiece stack-up, the workpiece stack-up comprising an aluminum-based workpiece and a steel workpiece, the aluminum-based workpiece having a faying surface and the steel workpiece having a faying surface, and wherein the faying surfaces of the aluminum-based workpiece and the steel workpiece overlap and contact one another to provide a faying interface between the workpieces; andcontrolling the passage of electrical current between the spot welding electrodes and through the aluminum-based workpiece and the steel workpiece to perform at least one stage of weld joint development that includes growing a molten weld pool in the aluminum-based workpiece that extends from the faying interface into ...

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Номер записи: 13
24-01-2019 дата публикации

FRICTION STIR BLIND RIVET JOINING SYSTEM AND METHOD

Номер: US20190022737A1
Автор: Carlson Blair E., Li Yongbing, Lin Zhongqin, Ma Yunwu
Принадлежит:

Friction stir blind rivet systems and methods are provided for joining workpieces. A FSBR joining system includes a mandrel with a head forming a tip. A stem extends from the head and has a narrowed section forming a notch. A tail section of the mandrel is configured to break off at the notch forming a broken end. A shank also has a head and a body, with a through-hole defined through the shank. The shank head includes a shoulder forming a surface contacting one workpiece. The head has an outermost point opposite the surface. A range is defined between the outermost point of the head and the surface. A wall projects from another workpiece and is formed around the body. The wall has a size formed by the mandrel and that is controlled to enable the body to deform. 1. A friction stir blind rivet (FSBR) joining system for joining workpieces comprising:a mandrel that has a first head forming a tip, with a stem extending from the first head, wherein the stem has a narrowed section forming a notch configured so that a tail section of the mandrel breaks-off, wherein the mandrel extends from the tip to a broken end;a shank that has a second head and a body extending from the second head, with a through-hole defined through the shank including through the second head and the body, wherein the second head includes a shoulder forming a surface, with the surface contacting one of the workpieces, and the second head has an outermost point opposite the surface, wherein a range is defined between the outermost point of the second head and the surface; anda wall projecting from another of the workpieces and formed around the body;wherein the wall has a size formed by the mandrel and that is controlled to enable the body to deform.3. The FSBR joining system of wherein the body is deformed by buckling to form annular sections that bulge outward against the workpieces.4. The FSBR joining system of wherein the notch is formed a distance dfrom the tip so that the broken end is disposed ...

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Номер записи: 14
02-02-2017 дата публикации

SYSTEMS AND METHODS FOR REINFORCED ADHESIVE BONDING

Номер: US20170028678A1
Автор: Carlson Blair E, Li Yongqiang, WANG JIANFENG, YANG XIN
Принадлежит:

The present disclosure relates to a bonding system () comprising an adhesive (), in contact with a first contact surface () and a second contact surface (), and a solder mesh () positioned in the adhesive () in contact with the first contact surface (). Also, the present disclosure relates to a bonding method to produce a solder-reinforced adhesive bond joining a first substrate () and a second substrate (), comprising applying, on a first contact surface () of the first substrate (), an adhesive (), positioning, at least partially into the adhesive (), a solder mesh (), such that the solder mesh () contacts the first contact surface (), connecting, to a portion of the adhesive () opposite the first contact surface (), a second contact surface () of the second substrate (), and applying heat to the first contact surface () such that at least one portion of the solder mesh () reaches a solder-bonding temperature. 1. A bonding system , comprising:an adhesive, in contact with a first contact surface of a first substrate and a second contact surface of a second substrate; anda solder mesh positioned at least partially in the adhesive, with at least one portion of the solder mesh being in contact with the first contact surface.2. The system of claim 1 , wherein the solder mesh is positioned in a distribution (i) arresting crack propagation or (ii) promoting crack propagation along a path requiring claim 1 , in at least one section of the system claim 1 , a greatest amount of fracture energy.3. The system of claim 1 , wherein the solder mesh comprises a coating configured to (i) arrest crack propagation in the adhesive or (ii) deflect crack propagation to promote failure in a shear direction through the adhesive adjacent the at the least one portion of the solder mesh.4. The system of claim 1 , wherein the solder mesh is further positioned in contact with the second contact surface.5. The system of claim 4 , wherein the solder mesh is positioned in a distribution (i) ...

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Номер записи: 15
02-02-2017 дата публикации

Systems And Methods For Reinforced Adhesive Bonding

Номер: US20170028679A1
Автор: Carlson Blair E., Li Yongqiang, WANG JIANFENG, YANG XIN
Принадлежит: GM GLOBAL TECHNOLOGY OPERATIONS LLC

The present disclosure relates to a bonding system () comprising an adhesive (), comprising thermoplastic material, in contact with a first contact surface () and a second contact surface (), and a plurality of solder particles () positioned in the adhesive () in contact with the first contact surface (). Also, the present disclosure relates to a bonding method to produce a solder-reinforced adhesive bond joining a first substrate () and a second substrate (), comprising applying, on a first contact surface () of the first substrate (), an adhesive () comprising thermoplastic material, positioning, at least partially into the adhesive (), each of a plurality of particles (), such that each of the plurality of solder balls () contacts the first contact surface (), connecting, to a portion of the adhesive () opposite the first contact surface (), a second contact surface () of the second substrate (), and applying heat to the first contact surface () such that each of the plurality of solder particles () reaches a solder bonding temperature. 1. A bonding system , comprising:an adhesive, comprising thermoplastic material, in contact with a first contact surface of a first substrate and a second contact surface of a second substrate; anda plurality of solder particles positioned at least partially in the adhesive, with at least one of the solder particles being in contact with the first contact surface,wherein the adhesive and the plurality of solder particles form a reversible bond between the first substrate and the second substrate.2. The system of claim 1 , wherein the plurality of solder particles are positioned in a distribution (i) arresting crack propagation or (ii) promoting crack propagation along a path requiring claim 1 , in at least one section of the system claim 1 , a greatest amount of fracture energy.3. The system of claim 1 , wherein the adhesive has a composition that promotes de-bonding of the first substrate and the second substrate during ...

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Номер записи: 16
11-02-2016 дата публикации

METHOD FOR JOINING WORKPIECES

Номер: US20160038993A1
Автор: Arinez Jorge F., Carlson Blair E., Lee SAUL S., Li Yongqiang
Принадлежит:

A method can be used for joining workpieces using a fastener. The fastener includes a first head and a shank extending from the first head along a fastener axis. The joining method includes the following steps: (a) rotating a fastener about a fastener axis; (b) moving the fastener toward the first and second workpieces while the fastener rotates about the fastener axis such that the fastener increases the temperature in the first and second workpieces in order to soften and pierce the first and second workpieces along the fastener axis; and (c) advancing the fastener through the first and second workpieces and toward an open cavity of a die after piercing the first and second workpieces while the fastener rotates about the fastener axis such that the shank is partially disposed inside the open cavity in order to form a second head. 1. A joining method , comprising:rotating a fastener about a fastener axis, wherein the fastener includes a first head and a shank extending from the first head along the fastener axis;moving the fastener toward a first workpiece and a second workpiece while the fastener rotates about the fastener axis such that the fastener increases a temperature in the first and second workpieces in order to soften and pierce the first and second workpieces along the fastener axis; andadvancing the fastener through the first and second workpieces and toward an open cavity of a die after piercing the first and second workpieces while the fastener rotates about the fastener axis such that the shank is partially disposed inside the open cavity in order to form a second head; andwherein the first workpiece is made of a first material, the second workpiece is made of a second material, and the fastener is made of a third material, the first material has a first softening temperature, the second material has a second softening temperature, the third material has a third softening temperature, and the third softening temperature is greater than the first and ...

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Номер записи: 17
09-02-2017 дата публикации

APERTURE PLATE FOR OVERHEATING PREVENTION AND WIRE NOZZLE PROTECTION

Номер: US20170036305A1
Автор: Carlson Blair E., Cox Aaron D., Perry Thomas A., Poss Michael G., WANG Hui-Ping
Принадлежит: GM GLOBAL TECHNOLOGY OPERATIONS LLC

An aperture plate for a welding apparatus includes a body defining an aperture. The body of the aperture plate includes a first end and a second end that is opposite the first end. In addition, the body includes a first surface intersecting the first and second ends. Moreover, the body includes a second surface formed opposite the first surface. The second surface is nonparallel to the first surface. 1. An aperture plate for a welding apparatus , said aperture plate comprising: a first end;', 'a second end opposite said first end;', 'a first surface intersecting said first and second ends; and', 'a second surface formed opposite said first surface and nonparallel to said first surface, such that electromagnetic radiation is reflected away from components of the welding apparatus., 'a body defining an aperture, said body comprising2. The aperture plate of claim 1 , wherein said first surface comprises at least one surface area increasing element disposed thereon.3. The aperture plate of claim 2 , wherein said at least one surface area increasing element comprises a channel defined in said first surface.4. The aperture plate of claim 1 , wherein at least a portion of said second surface comprises a polished surface.5. The aperture plate of claim 1 , wherein said second surface comprises a reflective coating layer formed on at least a portion of said second surface.6. The aperture plate of further comprising at least one fluid routing channel defined within said body between said first surface and said second surface.7. The aperture plate of claim 1 , wherein said first end comprises a first edge claim 1 , said second surface intersecting said first edge and sloped generally toward said first surface.8. The aperture plate of claim 1 , wherein at least a portion of said second surface comprises a concave surface claim 1 , said concave surface portion intersecting said first end and sloped generally toward said first surface.9. The aperture plate of claim 1 , wherein ...

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Номер записи: 18
03-03-2022 дата публикации

POST-BUILD QUICK POWDER REMOVAL SYSTEM FOR POWDER BED FUSION ADDITIVE MANUFACTURING

Номер: US20220063198A1
Автор: Anam MD Ashabul, Brown Tyson W., Carlson Blair E., CHAE HYUNGMIN, Poling Whitney A., Skurkis Richard J., Smith Mark A.
Принадлежит:

A post-build powder removal system includes a work bed, a platform wall having at least one powder evacuation port, and an evacuation port sealing system operable for selectively closing and opening the powder evacuation port. The platform wall cooperates with the work bed to define a powder chamber. The evacuation port sealing system includes an external sleeve slidingly fitted onto the exterior surface of the platform wall such that the external sleeve is slideable in a first direction closing the at least one powder evacuation port and slideable in an opposite second direction opening the at least one powder evacuation port. 1. A post-build powder removal system for a powder bed fusion system , comprising: a work bed;', 'a platform wall cooperating with the work bed to define a powder chamber, wherein the platform wall includes an interior surface, an exterior surface opposite the interior surface, and at least one port surface extending from the interior surface to the exterior surface to define at least one powder evacuation port in fluid communication with the powder chamber; and', 'an evacuation port sealing system operable for selectively closing and opening the powder evacuation port., 'a build platform including2. The post-build powder removal system of claim 1 , wherein the evacuation port sealing system includes:an external sleeve slidingly fitted onto the platform wall such that one of the platform wall and external sleeve is slideable in a first direction closing the at least one powder evacuation port and slideable in an opposite second direction opening the at least one powder evacuation port.3. The post-build powder removal system of claim 2 , wherein the external sleeve includes:an interior surface, an exterior surface opposite the interior surface, and at least one aperture surface defining an aperture extending from the interior surface to the exterior surface of the external sleeve,wherein the interior surface of the external sleeve is in ...

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Номер записи: 19
26-02-2015 дата публикации

RESISTANCE SPOT WELDING STEEL AND ALUMINUM WORKPIECES USING ELECTRODE WELD FACE COVER

Номер: US20150053654A1
Автор: Carlson Blair E., Karagoulis Michael J., Sigler David R.
Принадлежит:

A method of resistance spot welding a steel workpiece and an aluminum or aluminum alloy (“aluminum”) workpiece together includes several steps. One step involves providing a workpiece stack-up with a steel workpiece and an aluminum workpiece. Another step involves attaching a cover over a weld face of a welding electrode. The cover is made of a metal material with an electrical resistivity that is greater than an electrical resistivity of a material of the welding electrode. Yet another step involves performing multiple individual resistance spot welds to the workpiece stack-up. The cover abuts the aluminum workpiece while the individual resistance spot welds are performed. And another step involves removing the cover from the welding electrode after the individual spot welds are performed. 1. A method of resistance spot welding a steel workpiece and an aluminum or aluminum alloy workpiece together , the method comprising:providing a workpiece stack-up that includes a steel workpiece and an aluminum or aluminum alloy workpiece;attaching a cover at least over a weld face of a welding electrode, the cover being made of a metal material with an electrical resistivity that is greater than an electrical resistivity of a material of the welding electrode;performing a plurality of individual resistance spot welds to the workpiece stack-up, the cover abutting the aluminum or aluminum alloy workpiece while the individual resistance spot welds are performed; andremoving the cover from the welding electrode after the individual resistance spot welds are performed.2. The method as set forth in claim 1 , wherein the cover is attached to the welding electrode via a crimping process claim 1 , a stamping process claim 1 , a screwing process claim 1 , or a combination of two or more of these processes.3. The method as set forth in claim 1 , wherein the cover is made of steel claim 1 , stainless steel claim 1 , molybdenum claim 1 , tungsten claim 1 , or niobium.4. The method as set ...

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Номер записи: 20
26-02-2015 дата публикации

MULTI-STEP DIRECT WELDING OF AN ALUMINUM-BASED WORKPIECE TO A STEEL WORKPIECE

Номер: US20150053655A1
Автор: Carlson Blair E., Karagoulis Michael J., Myasnikova Yelena, Sigler David R.
Принадлежит:

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. The multiple stages include: (1) a molten weld pool growth stage in which a molten weld pool is initiated and grown within the aluminum-based workpiece; (2) a molten weld pool solidification stage in which the molten weld pool is allowed to cool and solidify into a weld nugget that forms all or part of a weld joint; (3) a weld nugget re-melting stage in which at least a portion of the weld nugget is re-melted; and (4) a re-melted weld nugget solidification stage in which the re-melted portion of the weld nugget is allowed to cool and solidify. 1. A method of resistance spot welding a workpiece stack-up , which includes an aluminum-based workpiece and a steel workpiece , so as to form a resistance spot weld joint between the aluminum-based workpiece and the steel workpiece , the method comprising:contacting a workpiece stack-up with a pair of spot welding electrodes such that the spot welding electrodes make contact with opposed sides of the workpiece stack-up, the workpiece stack-up comprising an aluminum-based workpiece and a steel workpiece, the aluminum-based workpiece having a faying surface and the steel workpiece having a faying surface, and wherein the faying surfaces of the aluminum-based workpiece and the steel workpiece overlap and contact one another to provide a faying interface between the workpieces; and growing a molten weld pool in the aluminum-based workpiece that extends from the faying interface into the aluminum-based workpiece;', 'allowing the molten weld pool to cool and solidify into a weld nugget that includes a weld bond area joined to the faying surface of the steel workpiece;', 're-melting at least a portion of the weld nugget including at least part of the weld ...

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Номер записи: 21
01-03-2018 дата публикации

INDUCTION ROTOR AND METHOD OF ASSEMBLING AN INDUCTION ROTOR

Номер: US20180062486A1
Автор: Agapiou John S., Carlson Blair E.
Принадлежит:

A rotor for an electromagnetic machine and a method of assembling the rotor are provided. In one embodiment, the rotor includes a lamination stack disposed about a rotational axis a plurality of conductor bars disposed within corresponding slots formed in the lamination stack and extending beyond the longitudinal ends of the lamination stack. End rings are positioned at either end of the lamination stack and define a plurality of openings configured to receive the ends of the conductor bars. Each end ring includes separate inner and outer concentric rings. The inner and outer rings define radially outer and inner surfaces configured to abut one another and each of the concentric rings defines a portion of each conductor bar opening in the end ring. 1. A rotor for an electromagnetic machine , comprising:a lamination stack disposed about a rotational axis and having first and second ends, the lamination stack including a plurality of adjacent laminations defining a plurality of slots extending between the first and second ends;a plurality of conductor bars, each conductor bar of the plurality of conductor bars disposed within a corresponding slot of the plurality of slots and extending beyond the first and second ends of the lamination stack; andfirst and second end rings disposed at the first and second ends of the lamination stack, each of the first and second end rings defining a plurality of openings and each opening of the plurality of openings configured to receive a corresponding conductor bar of the plurality of conductor bars;wherein each of the first and second end rings includes separate inner and outer concentric rings, the inner concentric ring defining a radially outer surface and a first portion of each opening of the plurality of openings and the outer concentric ring defining a radially inner surface and second portion of each opening of the plurality of openings, the radially outer surface of the inner concentric ring configured to abut the radially ...

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Номер записи: 22
05-06-2014 дата публикации

Bimetallic casting

Номер: US20140150985A1
Автор: Blair E. Carlson, Paul E. Krajewski
Принадлежит: GM GLOBAL TECHNOLOGY OPERATIONS LLC

A method of forming a casting includes providing a preform to a mold cavity. The preform is formed from one of a first metal and a second metal and defines an interface surface. A molten portion of the other of the first metal and the second metal is cast into the mold such that the molten portion proximately contacts the interface surface of the preform. An interface layer at the interface surface, a first portion defined by the mold cavity and the interface layer, and a second portion defined by the interface layer, are formed during casting. The interface layer may define a metallurgical bond between the first portion and the second portion. In the non-limiting example provided herein, the first portion is substantially comprised of aluminum and the second portion is substantially comprised of magnesium. In a non-limiting example, the casting may be configured as a vehicle wheel.

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Номер записи: 23
16-03-2017 дата публикации

ADDITIVE ENERGY DIRECTOR AND METHOD OF FORMATION

Номер: US20170072433A1
Автор: Arinez Jorge F., Carlson Blair E., Lee SAUL S., Li Yongqiang
Принадлежит:

A method of forming additive energy directors according to various exemplary embodiments can include dispensing a molten material onto a substrate at a predetermined location. The method also includes solidifying the molten material to form at least one additive energy director onto the substrate. 1. A method , for forming an additive energy director , comprising:dispensing a molten material onto a substrate at a predetermined location; andforming an additive energy director on the substrate by solidifying the molten material on the substrate.2. The method of claim 1 , wherein the dispensing comprises dispensing the molten material utilizing a drop-on-demand fluid drop emitting device.3. The method of claim 1 , wherein the dispensing comprises dispensing the molten material utilizing a drop-on-demand fluid drop emitting device employing one or more nozzles to dispense the molten material.4. The method of claim 1 , wherein the dispensing comprises dispensing the molten material through multiple passes over the substrate utilizing a drop-on-demand fluid drop emitting device.5. The method of claim 1 , wherein the dispensing comprises dispensing the molten material during multiple passes over the substrate utilizing a drop-on-demand fluid drop emitting device to selectively increase a drop density of the molten material dispensed onto the substrate.6. The method of claim 1 , wherein the dispensing comprises dispensing the molten material during multiple passes over the substrate utilizing a drop-on-demand fluid drop emitting device to selectively increase a drop size of the molten material dispensed onto the substrate.7. The method of claim 1 , wherein the dispensing comprises dispensing the molten material utilizing a spray process.8. The method of claim 1 , wherein the dispensing comprises dispensing the molten material utilizing a continuous stream process.9. The method of claim 2 , further comprising forming the energy director by applying a three-dimensional ...

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Номер записи: 24
14-03-2019 дата публикации

WELDING ELECTRODE DESIGN

Номер: US20190076955A1
Автор: Carlson Blair E., Haselhuhn Amberlee S., Karagoulis Michael J., Sigler David R., WANG Hui-Ping
Принадлежит:

A welding electrode includes a weld face that has a convex base weld face surface and a plurality of ringed ridges that are radially spaced apart on the base weld face surface and surround a central weld face axis. The plurality of ringed ridges including an innermost ringed ridge and an outermost ringed ridge. The innermost ringed ridge is located closest to the central weld face axis and rises above a central portion of the base weld face surface, and the outermost ringed ridge is located farthest from the central weld face axis and rises above an outer peripheral portion of the base weld face surface. At least one of the plurality of ringed ridges is a discontinuous ringed ridge. 1. A welding electrode comprising:a body; anda weld face disposed at one end of the body, the weld face including a convex base weld face surface that rises upwardly along a central weld face axis and a plurality of ringed ridges that are radially spaced apart on the base weld face surface and surround the central weld face axis, the plurality of ringed ridges including an innermost ringed ridge and an outermost ringed ridge, the innermost ringed ridge being located closest to the central weld face axis and rising above a central portion of the base weld face surface, and the outermost ringed ridge being located farthest from the central weld face axis and rising above an outer peripheral portion of the base weld face surface;wherein at least two of the plurality of ringed ridges that are located radially adjacent to one another are discontinuous ringed ridges, each of the discontinuous ringed ridges comprising a plurality of circumferentially spaced apart arcuate ridge portions that extend along a circular base line of the ridge and rise upwardly from the base weld face surface, wherein the circumferentially spaced apart arcuate ridge portions of each of the discontinuous ringed ridges define two or more ridge gaps along the circular base line of each discontinuous ringed ridge, and ...

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Номер записи: 25
31-03-2022 дата публикации

LASER WELDED ASSEMBLY HAVING A HEAT AFFECTED ZONE REINFORCEMENT AND METHOD OF MAKING THE SAME

Номер: US20220097172A1
Автор: Carlson Blair E., Chen Nannan, Solomon Joshua L., Torres Guzman Paulina G., Wan Zixuan, WANG Hui-Ping
Принадлежит:

A laser welded assembly and method of making. The laser welded assembly includes a first work piece having a thickness (T) defined between an external surface and a faying surface; a second work piece having a thickness (T) defined between an external surface and a faying surface of the second work piece; a weld seam having a core fusion zone extending from the external surface of the first work piece through the faying interface and at least partially into the thickness (T) of the second work piece; and a protruding fusion zone extending laterally from the core fusion zone adjacent to the external surface of the first work piece. The protruding fusion zone may be formed by post-heating or concurrently with the core fusion zone. 1. A welded assembly comprising ,{'b': '1', 'a first work piece having an external surface, a faying surface opposite the external surface, and a thickness (T) defined between the external surface and the faying surface of the first work piece;'}{'b': '2', 'a second work piece having an external surface, a faying surface opposite the external surface, and a thickness (T) defined between the external surface and the faying surface of the second work piece, wherein the faying surface of the first work piece is in abutting contact with the faying surface of the second work piece to define a faying interface;'}{'b': '2', 'a weld seam having a core fusion zone extending from the external surface of the first work piece through the faying interface and at least partially into the thickness (T) of the second work piece; and'}a protruding fusion zone extending laterally from the core fusion zone adjacent to the external surface of the first work piece.2121212. The weld assembly of claim 1 , wherein the protruding fusion zone includes a boundary defined between a first radius (R) adjacent to the external surface of the first work piece and a second radius (R) proximal to the faying interface claim 1 , wherein the first radius (R) and second radius (R ...

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Номер записи: 26
09-04-2015 дата публикации

RESISTANCE SPOT WELDING STEEL AND ALUMINUM WORKPIECES USING INSERTABLE COVER

Номер: US20150096961A1
Автор: Carlson Blair E., Sachdev Anil K., Sigler David R., Szymanski Robert T., Yang David
Принадлежит:

A method of resistance spot welding a steel workpiece and an aluminum or aluminum alloy workpiece together includes several steps. One step involves inserting a cover between the aluminum or aluminum alloy workpiece and an adjacent welding electrode. In another step, the adjacent welding electrode is pressed against cover, and another opposed welding electrode is pressed against the steel workpiece at a weld site. In yet another step, electrical current is passed between the welding electrodes, passed through the cover, and passed through the workpieces in order to initiate and grow a molten weld pool within the aluminum or aluminum alloy workpiece. 1. A method of resistance spot welding a steel workpiece and an aluminum or aluminum alloy workpiece together , the method comprising:providing a workpiece stack-up that includes a steel workpiece and an aluminum or aluminum alloy workpiece, and providing a first welding electrode confronting the steel workpiece and a second welding electrode confronting the aluminum or aluminum alloy workpiece;inserting a cover between the aluminum or aluminum alloy workpiece and the second welding electrode, the cover being made of a metal;pressing the first welding electrode against the steel workpiece and the second welding electrode against the cover at a weld site; andpassing electrical current between the first and second welding electrodes, through the workpiece stack-up, and through the cover to initiate and grow a molten weld pool within the aluminum or aluminum alloy workpiece.2. The method as set forth in claim 1 , wherein the second welding electrode is composed of a material having an electrical resistivity claim 1 , and wherein the cover has an electrical resistivity that is greater than the electrical resistivity of the second welding electrode.3. The method as set forth in claim 2 , wherein the cover is made of a stainless steel claim 2 , molybdenum or a molybdenum-based alloy claim 2 , niobium or a niobium-based alloy ...

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Номер записи: 27
09-04-2015 дата публикации

Aluminum Alloy to Steel Welding Process

Номер: US20150096962A1
Автор: Carlson Blair E., Myasnikova Yelena, Schroth James G., Sigler David R., Yang David
Принадлежит:

A resistance spot welding method may involve spot welding a workpiece stack-up that includes a steel workpiece and an aluminum alloy workpiece that overlap one another to provide a faying interface. A pair of opposed welding electrodes are pressed against opposite sides of the workpiece stack-up with one welding electrode contacting the aluminum alloy workpiece and the other welding electrode contacting the steel workpiece. The welding electrodes are constructed so that, when an electrical current is passed between the electrodes and through the workpiece stack-up, the electrical current has a greater current density in the steel workpiece than in the aluminum alloy workpiece to thereby concentrate heat within a smaller zone in the steel workpiece. Concentrating heat within a smaller zone in the steel workpiece is believed to modify the solidification behavior of the resultant molten aluminum alloy weld pool in a desirable way. 1. A method of spot welding a steel workpiece to an aluminum alloy workpiece , the method comprising:providing a stack-up that includes a steel workpiece and an aluminum alloy workpiece, the steel workpiece and the aluminum alloy workpiece overlapping to provide a faying interface;contacting an electrode-contacting surface of the steel workpiece with a steel welding electrode;contacting an electrode-contacting surface of the aluminum alloy workpiece with an aluminum alloy welding electrode;passing an electrical current between the steel and aluminum alloy welding electrodes and through the stack-up to initiate a molten aluminum alloy weld pool within the aluminum alloy workpiece and at the faying interface, the electrical current having a greater current density in the steel workpiece than in the aluminum alloy workpiece; andceasing passage of the electrical current at which time a contact patch formed by the aluminum alloy welding electrode at the electrode-contacting surface of the aluminum alloy workpiece is greater in surface area than a ...

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Номер записи: 28
26-06-2014 дата публикации

Fabricated-in-place inserts to receive self-piercing rivets

Номер: US20140178152A1
Автор: Blair E. Carlson, Pei-Chung Wang
Принадлежит: GM GLOBAL TECHNOLOGY OPERATIONS LLC

One or more ductile metal inserts may be selectively incorporated into articles of limited ductility, including metal castings and molded polymers. The inserts are positioned at joint locations for joining of the article to other articles using self-piercing riveting (SPR). The inserts are of suitable ductility, thickness and strength to receive and retain self-piercing rivets and enable a strong riveted joint between the article and a second article. In an embodiment the articles are magnesium alloy castings formed by any of sand casting, die casting and semi-solid metal casting. The chemical composition of the insert may be informed by the anticipated corrosive environment of the joint and the casting temperature of the magnesium alloy. For magnesium alloy castings which may be exposed to corrosive environments, aluminum alloy inserts are preferred.

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Номер записи: 29
20-04-2017 дата публикации

MULTI-STAGE RESISTANCE SPOT WELDING METHOD FOR WORKPIECE STACK-UP HAVING ADJACENT STEEL AND ALUMINUM WORKPIECES

Номер: US20170106466A1
Автор: Carlson Blair E., Karagoulis Michael J., Sigler David R.
Принадлежит:

A workpiece stack-up that includes at least a steel workpiece and an adjacent and overlapping aluminum workpiece can be resistance spot welded by a multi-stage spot welding method. The multi-stage spot welding method involves initially forming a weld joint between the steel and aluminum workpieces. The weld joint extends into the aluminum workpiece from the faying interface of the two workpieces and includes an interfacial weld bond area adjacent to and joined with the faying surface of the steel workpiece. After the weld joint is initially formed, the multi-stage spot welding method calls for remelting and resolidifying at least a portion of the weld joint that includes some or all of the interfacial weld bond area. At least a portion of the resultant refined weld joint may then be subjected to the same remelting and resolidifying practice, if desired. Multiple additional practices of remelting and resolidifying may be carried out. 1. A method of resistance spot welding a workpiece stack-up that includes a steel workpiece and an aluminum workpiece , the method comprising:(a) providing a workpiece stack-up that has a first side and a second side, the workpiece stack-up comprising a steel workpiece disposed adjacent to and overlapping an aluminum workpiece, the steel workpiece having a faying surface that contacts a faying surface of the aluminum workpiece to establish a faying interface between the workpieces;(b) passing an electrical current across the faying interface to cause melting of the aluminum workpiece and the formation of a molten aluminum weld pool within the aluminum workpiece that wets the faying surface of the steel workpiece;(c) allowing the molten aluminum weld pool to solidify into a weld joint that bonds the steel and aluminum workpieces together at the faying interface, the weld joint having an interfacial weld bond area joined with the faying surface of the steel workpiece;(d) passing an electrical current through the weld joint to remelt at ...

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Номер записи: 30
20-04-2017 дата публикации

TAILORED PANEL ASSEMBLY AND METHOD OF MANUFACTURING THE SAME

Номер: US20170106625A1
Автор: Brown Tyson W., Carlson Blair E., Carter Jon T., Mishra Raja K., Sachdev Anil K., Saje Robert N., Sigler David R., Simonin Matthew P.
Принадлежит: GM GLOBAL TECHNOLOGY OPERATIONS LLC

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. 1. A method of manufacturing a panel assembly , the method comprising:forming a plurality of bonds between a first sheet material and a second sheet material of a laminated sheet to bond the first and second sheet materials in a face to face relationship to form a preform, the plurality of bonds defining a closed perimeter region between the first and second sheet materials and an open perimeter region between the first and second sheet materials;forming the preform into a predefined shape of the panel assembly;applying a pressurized fluid through at least one inlet coupled in fluid communication with the open perimeter region between the first and second sheet materials of the preform to expand the preform, wherein the pressurized fluid expands the open perimeter region between the first and second sheet materials, wherein the first and second sheet materials expand in an opposing direction thereby defining an expanded open perimeter region, and wherein the closed perimeter region between the first and second sheet materials remains vacant ...

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Номер записи: 31
11-04-2019 дата публикации

ALUMINUM ALLOY TO STEEL WELDING PROCESS

Номер: US20190105728A1
Автор: Carlson Blair E., Myasnikova Yelena, Schroth James G., Sigler David R., Yang David
Принадлежит:

A resistance spot welding method may involve spot welding a workpiece stack-up that includes a steel workpiece and an aluminum alloy workpiece. A pair of opposed welding electrodes are pressed against opposite sides of the workpiece stack-up with one welding electrode contacting the aluminum alloy workpiece and the other welding electrode contacting the steel workpiece. The welding electrodes are constructed so that, when an electrical current is passed between the electrodes and through the workpiece stack-up, the electrical current has a greater current density in the steel workpiece than in the aluminum alloy workpiece to thereby concentrate heat within a smaller zone in the steel workpiece. Concentrating heat within a smaller zone in the steel workpiece is believed to modify the solidification behavior of the resultant molten aluminum alloy weld pool in a desirable way. 1. A method of spot welding a workpiece stack-up that includes a steel workpiece and an aluminum alloy workpiece , the method comprising:providing a stack-up that includes a steel workpiece and an aluminum alloy workpiece;contacting an electrode-contacting surface of the steel workpiece with a steel welding electrode;contacting an electrode-contacting surface of the aluminum alloy workpiece with an aluminum alloy welding electrode;passing an electrical current between the steel and aluminum alloy welding electrodes and through the stack-up, the electrical current having a greater current density in the steel workpiece than in the aluminum alloy workpiece; andceasing passage of the electrical current at which time a contact patch formed by the aluminum alloy welding electrode at the electrode-contacting surface of the aluminum alloy workpiece is greater in surface area than a contact patch formed by the steel welding electrode at the electrode-contacting surface of the steel workpiece, the contact patch formed by the aluminum alloy welding electrode having a surface area that is greater than the ...

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Номер записи: 32
28-04-2016 дата публикации

LASER CONDUCTION MODE WELDING OF ALUMINUM ALLOYS WITH CROSS DUAL LASER BEAMS

Номер: US20160114428A1
Автор: Carlson Blair E., Gatny David A., Leggett Perry G., Poss Michael G., WANG Hui-Ping
Принадлежит:

A method of laser welding aluminum alloy workpieces with dual laser beams arranged in a cross-beam orientation is disclosed. The method comprises directing dual laser beams, which include a first laser beam and a second laser beam, at and along a weld seam established between the aluminum alloy workpieces together with a filler wire. The first laser beam includes a first longitudinal axis and the second laser beam includes a second longitudinal axis. When arranged in the cross-beam orientation, a plane that intersects the first longitudinal axis and the second longitudinal axis of the first and second laser beams, respectively, forms a line where it meets the aluminum alloy workpieces that is oriented transverse to the weld seam. 1. A method of laser welding aluminum alloy workpieces , the method comprising:providing a first aluminum alloy workpiece and a second aluminum alloy workpiece that are brought together to form a weld seam;directing dual laser beams toward the weld seam established between the aluminum alloy workpieces, the dual laser beams comprising a first laser beam extending along a first longitudinal axis and a second laser beam extending along a second longitudinal axis, and wherein a plane that intersects the first and the second longitudinal axes of the first and second laser beams forms a line where the plane meets the first and second aluminum alloy workpieces that is transverse to the weld seam;moving the dual laser beams along the weld seam together with a filler wire without producing a keyhole that penetrates into the first and second aluminum alloy workpieces, the filler wire having a working end that tracks the weld seam and is impinged by both the first and second laser beams at the weld seam; andmelting the working end of the filler wire with the dual laser beams to deposit molten filler material along the weld seam as the dual laser beams and the filler wire are moved along the weld seam, the molten filler material solidifying behind the ...

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Номер записи: 33
26-04-2018 дата публикации

HOT CRACKING REDUCTION IN ALUMINUM LASER WELDING

Номер: US20180111226A1
Автор: Carlson Blair E., Cui Haichao, Lu Fenggui, Poss Michael G., WANG Hui-Ping
Принадлежит:

A method of laser welding a workpiece stack-up that includes two or three overlapping aluminum alloy workpieces involves constraining a free end of an overlapping portion of a first aluminum alloy workpiece against movement away from an underlying second aluminum alloy workpiece to counteract the thermally-induced forces that cause out-of-plane deformation of one or more of the aluminum alloy workpieces during laser welding. Such constraint of the free end of the first aluminum alloy workpiece may be accomplished by clamping, spot welding, or any other suitable practice. By constraining the free end of the first aluminum alloy workpiece, and thus inhibiting out-of-plane deformation of the aluminum alloy workpieces when laser welding is practiced in a nearby welding region, the occurrence of hot cracking is minimized or altogether eliminated in the final laser weld joint. 1. A method of laser welding a workpiece stack-up that includes two or three aluminum alloy workpieces , the method comprising:providing a workpiece stack-up that includes at least a first aluminum alloy workpiece and an underlying second aluminum alloy workpiece that overlap and contact one another to establish a first faying interface between the workpieces, the first aluminum alloy workpiece providing a top surface of the workpiece stack-up;constraining a free end of an overlapping portion of the first aluminum alloy workpiece against movement away from the underlying second aluminum alloy workpiece;directing a laser beam at the top surface of the workpiece stack-up to create a keyhole within the workpiece stack-up and a molten aluminum alloy weld pool that surrounds the keyhole, the molten aluminum alloy weld pool traversing at least the first faying interface established between the first and second aluminum alloy workpieces; andconveying the laser beam and the associated keyhole and molten aluminum alloy weld pool relative to the top surface of the workpiece stack-up along a travel path within ...

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Номер записи: 34
27-04-2017 дата публикации

Fabricated-in-place inserts to receive self-piercing rivets

Номер: US20170114815A1
Автор: Blair E. Carlson, Pei-Chung Wang
Принадлежит: GM GLOBAL TECHNOLOGY OPERATIONS LLC

One or more ductile metal inserts may be selectively incorporated into articles of limited ductility, including metal castings and molded polymers. The inserts are positioned at joint locations for joining of the article to other articles using self-piercing riveting (SPR). The inserts are of suitable ductility, thickness and strength to receive and retain self-piercing rivets and enable a strong riveted joint between the article and a second article. In an embodiment the articles are magnesium alloy castings formed by any of sand casting, die casting and semi-solid metal casting. The chemical composition of the insert may be informed by the anticipated corrosive environment of the joint and the casting temperature of the magnesium alloy. For magnesium alloy castings which may be exposed to corrosive environments, aluminum alloy inserts are preferred.

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Номер записи: 35
18-04-2019 дата публикации

TAILORED PANEL ASSEMBLY AND METHOD OF MANUFACTURING THE SAME

Номер: US20190115004A1
Автор: Brown Tyson W., Carlson Blair E., Carter Jon T., Mishra Raja K., Sachdev Anil K., Saje Robert N., Sigler David R., Simonin Matthew P.
Принадлежит: GM GLOBAL TECHNOLOGY OPERATIONS LLC

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. 1. A panel assembly comprising:a first sheet material;a second sheet material bonded to the first sheet material by a plurality of bonds, the plurality of bonds defining a closed perimeter region between the first and second sheet materials and an open perimeter region between the first and second sheet materials;a filler material disposed within the open perimeter region;wherein the closed perimeter region between the first and second sheet materials remains vacant of the filler material; andwherein the open perimeter region defines a structural load path for transmitting a force between a first location of the panel assembly and a second location of the panel assembly.2. The panel assembly set forth in claim 1 , wherein the filler material is one of a sound deadening material claim 1 , a stiffness controlling material claim 1 , an insulating material claim 1 , or a strength controlling material.3. The panel assembly set forth in claim 1 , wherein the filler material is controllable in response to a control signal to change a physical ...

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Номер записи: 36
03-05-2018 дата публикации

METHODS AND SYSTEMS FOR REINFORCED ADHESIVE BONDING USING SOLDER ELEMENTS AND FLUX

Номер: US20180117694A1
Автор: Carlson Blair E., Li Yongbing, YANG XIN
Принадлежит:

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. 1. A bonding system formed by a process comprising:providing a first substrate having a first contact surface and a second substrate having a second contact surface, opposite the first contact surface;applying to the first contact surface a flux coating;applying to the first contact surface a solder-adhesive mixture comprising an adhesive and a plurality of solder elements in at least a portion of the adhesive, wherein the solder-adhesive mixture is heated to at least partially melt or at least partially vaporize the flux coating upon contact therewith, thereby promoting a bonding condition between the solder-adhesive mixture and the first substrate; andpositioning the second contact surface adjacent the solder-adhesive mixture, wherein the second contact surface is opposite the first contact surface.2. The product of the process of claim 1 , wherein the solder-adhesive mixture is heated to a flux melting temperature.3. The product of the process of claim 1 , wherein the flux coating is applied to the second contact surface prior to application of the solder-adhesive mixture.4. The product of the process of claim 1 , wherein at least one of the plurality of solder elements is in contact ...

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Номер записи: 37
03-05-2018 дата публикации

METHODS AND SYSTEMS FOR REINFORCED ADHESIVE BONDING USING SOLDER ELEMENTS AND FLUX

Номер: US20180117716A1
Автор: Carlson Blair E., Li Yongbing, YANG XIN
Принадлежит:

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. 1. A bonding system formed by a process comprising:providing a first substrate having a first contact surface and a second substrate having a second contact surface, opposite the first contact surface;applying to the first contact surface a flux coating;applying to the first contact surface a solder-adhesive mixture comprising an adhesive and a plurality of solder elements in at least a portion of the adhesive;positioning the second contact surface adjacent the solder-adhesive mixture; andapplying heat to the solder-adhesive mixture by way of at least one of the first and second contact surfaces such that the solder-adhesive mixture is heated to at least partially melt or at least partially vaporize the flux coating upon contact therewith, thereby promoting a bonding condition between the solder-adhesive mixture and the first substrate.2. The product of the process of claim 1 , wherein the flux coating is applied to the second contact surface prior to application of the solder-adhesive mixture.3. The product of the process of claim 1 , wherein at least one of the plurality of solder elements is in ...

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Номер записи: 38
25-04-2019 дата публикации

METHOD FOR LASER WELDING STEEL WORKPIECES

Номер: US20190118307A1
Автор: Carlson Blair E., Pan Yu, Payne William P., Solomon Joshua L., Tao Wu, WANG Hui-Ping, Yang David
Принадлежит:

A method of laser welding a workpiece stack-up () of overlapping steel workpieces () involves heat-treating a region () of the stack-up () followed by forming a laser weld joint () that is located at least partially within the heat-treated region (). During heat-treating, one or more pre-welding laser beams () are sequentially directed at a top surface () of the workpiece stack-up () and advanced along a pre-welding beam travel pattern () so as to reduce an amount of vaporizable zinc within the stack-up (). Thereafter, the laser weld joint () is formed by directing a welding laser beam () at the top surface () of the workpiece stack-up () and advancing the welding laser beam () along a welding beam travel pattern () that at least partially overlaps with a coverage area of a pre-welding beam travel pattern () or a shared coverage area portion of multiple pre-welding beam travel patterns (). The method can help reduce an amount of vaporizable zinc within the stack-up (). 1. A method of laser welding overlapping steel workpieces , the method comprising:providing a workpiece stack-up that includes overlapping steel workpieces, the workpiece stack-up comprising at least a first steel workpiece and a second steel workpiece that overlap at a weld site, the first steel workpiece providing a top surface of the workpiece stack-up and the second steel workpiece providing a bottom surface of the workpiece stack-up, wherein a faying interface is established between each pair of adjacent overlapping steel workpieces within the workpiece stack-up at the weld site, and wherein at least one of the steel workpieces in the workpiece stack-up includes a surface coating of a zinc-based material;heat-treating a region of the workpiece stack-up to heat and vaporize at least one surface coating of a zinc-based material so as to reduce an amount of vaporizable zinc within the region;directing a welding laser beam at the top surface of the workpiece stack-up after heat-treating, the welding ...

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Номер записи: 39
09-05-2019 дата публикации

ELECTRODE WELD FACE DESIGN

Номер: US20190134735A1
Автор: Carlson Blair E., Haselhuhn Amberlee S., Sigler David R.
Принадлежит:

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. 1. A welding electrode comprising:a body having a front end and an opposite back end; anda weld face supported on the front end of the body, the weld face comprising 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 having a base dome face surface and a series of radially-spaced ringed ridges, each of the series of radially-spaced ringed ridges on the central dome portion projecting outwardly from the base dome face surface and surrounding a central axis of the weld face, the series of radially-spaced ringed ridges on the central dome portion including an innermost ringed ridge that is closest to the central axis of the weld face and an outermost ringed ridge that is farthest from the central axis of the weld face such that the series of radially-spaced ringed ridges on the central dome portion increases in plan diameter from the innermost ringed ridge to the outermost ringed ridge, the outermost ringed ridge on the ...

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Номер записи: 40
09-05-2019 дата публикации

METHOD OF COATING BODY-IN-WHITE STRUCTURE HAVING AT LEAST ONE SURFACE COMPRISING AN ALUMINUM ALLOY

Номер: US20190136401A1
Автор: Carlson Blair E., Maddela Surender
Принадлежит:

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. 1. A method of forming an adhesion promoting layer and a corrosion resistant layer over surfaces of a body-in-white (“BIW”) structure , the method comprising:pre-activating surfaces of the BIW structure, wherein the surfaces of the BIW structure comprise at least an aluminum alloy surface and a metallic surface comprising a metal selected from the group consisting of: iron (Fe), zinc (Zn), titanium (Ti), zirconium (Zr), and alloys and combinations thereof, by immersing the BIW structure in a pre-activating bath to form pre-activated surfaces on the BIW structure;forming an adhesion promoting layer comprising cerium over the pre-activated surfaces of the BIW structure by immersing the pre-activated surfaces of the BIW structure in an aqueous bath comprising a source of cerium cations and a polymer precursor, wherein a potential is applied to the aqueous bath and the cerium cations coat the pre-activated surfaces of the BIW structure to form the adhesion promoting layer comprising cerium over the surfaces of the BIW structure; andforming a corrosion resistant layer comprising a polymer formed from the polymer precursor over the adhesion promoting layer comprising cerium while the potential is applied to the aqueous ...

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Номер записи: 41
07-05-2020 дата публикации

MECHANICAL PERFORMANCE OF AL-STEEL WELD JOINTS

Номер: US20200139480A1
Автор: Carlson Blair E., Haselhuhn Amberlee S., Karagoulis Michael J., Sigler David R.
Принадлежит:

A method of resistance spot welding a workpiece stack-up that includes a steel workpiece and an aluminum workpiece includes adhering an aluminum patch to faying surface of a steel workpiece, positioning an aluminum workpiece over the aluminum patch and the steel workpiece to assemble a workpiece stack-up, passing an electric current through the workpiece stack-up to create a molten aluminum weld pool, and terminating passage of the electric current to solidify the molten aluminum weld pool into a weld joint that bonds the steel and aluminum workpieces together through the aluminum patch. A workpiece stack-up having a weld joint that bonds an aluminum workpiece and a steel workpiece together through an aluminum patch is also disclosed. The weld joint establishes a bonding interface with the faying surface of the steel workpiece, and the aluminum patch is adhered to the faying surface of the steel workpiece around the weld joint. 1. A method of resistance spot welding a workpiece stack-up that includes a steel workpiece and an aluminum workpiece , the method comprising:adhering an aluminum patch to a faying surface of a steel workpiece;positioning an aluminum workpiece over the aluminum patch and the steel workpiece to assemble a workpiece stack-up in which the aluminum patch is disposed between a faying surface of the aluminum workpiece and the faying surface of the steel workpiece, the workpiece stack-up having a first side and an opposite second side, the first side being provided by an aluminum workpiece surface and the second side being provided by a steel workpiece surface;pressing a weld face of a first welding electrode against the first side of the workpiece stack-up;pressing a weld face of a second welding electrode against the second side of the workpiece stack-up in facial alignment with the weld face of the first welding electrode;passing an electric current between the weld face of the first welding electrode and the weld face of the second welding ...

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Номер записи: 42
09-06-2016 дата публикации

RESISTANCE SPOT WELDING STEEL AND ALUMINUM WORKPIECES WITH ELECTRODE INSERT

Номер: US20160158874A1
Автор: Carlson Blair E., Sigler David R., Wang Pei-Chung
Принадлежит:

A method of resistance spot welding a steel workpiece and an aluminum or aluminum alloy workpiece together includes several steps. In one step a workpiece stack-up is provided. The workpiece stack-up includes a steel workpiece and an aluminum or aluminum alloy workpiece. Another step involves providing a first welding electrode that confronts the aluminum workpiece, and providing a second welding electrode that confronts the steel workpiece. The first welding electrode has an electrode body and an insert that functions to limit or eliminate heat flux into the electrode body. Other steps of the method involve bringing the first and second welding electrodes into contact with opposite sides of the workpiece stack-up and resistance spot welding the stack-up. 1. A method of resistance spot welding a steel workpiece and an aluminum or aluminum alloy workpiece , the method comprising:providing a workpiece stack-up that includes a steel workpiece and an aluminum or aluminum alloy workpiece;providing a first welding electrode generally confronting the aluminum or aluminum alloy workpiece and a second welding electrode generally confronting the steel workpiece, the first welding electrode having an electrode body and an insert located at or adjacent a weld face of the first welding electrode, the insert having at least a peripheral portion adjacent to the surrounding electrode body that has an electrical conductivity less than or equal to approximately 20% of the electrical conductivity of commercially pure annealed copper as defined by the IACS as well as a thermal conductivity that is less than or equal to approximately 20% of the thermal conductivity of commercially pure annealed copper;bringing the first and second welding electrodes into contact with opposite sides of the workpiece stack-up with the first welding electrode making contact with the aluminum or aluminum alloy workpiece and the second welding electrode making contact with the steel workpiece; andresistance ...

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Номер записи: 43
23-07-2015 дата публикации

SUPPRESSING LASER-INDUCED PLUME FOR LASER EDGE WELDING OF ZINC COATED STEELS

Номер: US20150202718A1
Автор: Carlson Blair E., Gatny David A., Wang Jeff, Yang David
Принадлежит: GM GLOBAL TECHNOLOGY OPERATIONS LLC

A system and method for stabilizing the molten pool in a laser welding operation by suppressing a laser-induced plume which occurs when zinc coated steels are laser welded. The plume is a result of vaporization of zinc, and the zinc vapor in the plume disturbs the molten pool and causes blowholes, spattering and porosity. The stabilization is achieved by applying a gas such as air through a nozzle to the weld area, where the gas has sufficient velocity and flow rate to blow the zinc vapor away from the molten pool. Dramatically improved weld quality results have been demonstrated. Configuration parameters which yield optimum results—including gas flow rate and velocity, and nozzle position and orientation relative to the laser impingement location on the steel—are disclosed. 1. An apparatus for suppressing a plasma and vapor plume when laser welding zinc coated sheets , said apparatus comprising:a fixture upon which other components of the apparatus are mounted, where the fixture moves along a direction of motion and the sheets which are being welded are stationary;a welding laser mounted to the fixture and directed to a weld point, where the weld point is a point where the laser impinges the sheets which are being welded; anda shielding gas provision system mounted to the fixture, said shielding gas provision system including a nozzle, where the nozzle provides a flow of a shielding gas, and where the flow of the shielding gas has a velocity of at least 10 meters/second and a mass flow rate of at least 10 grams/second, and during welding the flow of the shielding gas dissipates the plasma and vapor plume and prevents the plume from adversely affecting weld quality.2. The apparatus of wherein the flow of the shielding gas has a velocity in a range of 30-120 meters/second.3. The apparatus of wherein the flow of the shielding gas has a mass flow rate in a range of 10-660 grams/second.4. The apparatus of wherein the nozzle is positioned ahead of the welding laser ...

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Номер записи: 44
14-07-2016 дата публикации

Rivet with cutting mandrel tip and one-sided joining method

Номер: US20160201709A1
Автор: Blair E. Carlson, Junying Min, Shixin Jack HU, Yongqiang Li
Принадлежит: GM GLOBAL TECHNOLOGY OPERATIONS LLC, University of Michigan

A product and method for fastening workpiece elements. A rivet assembly may include a mandrel with a cutting edge that forms an opening in the workpiece elements as the rivet body is positioned through the workpiece elements.

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Номер записи: 45
27-07-2017 дата публикации

SYSTEMS AND METHODS FOR REINFORCED ADHESIVE BONDING

Номер: US20170209948A1
Автор: Carlson Blair E., Li Yongqiang, WANG JIANFENG, YANG XIN
Принадлежит:

The present disclosure relates to a method, to distribute a solder-reinforced adhesive on a first substrate (), comprising (i) positioning the first substrate () to receive an adhesive composite () including, an adhesive () and a plurality of solder balls () on a first contact surface () of the first substrate (), (ii) applying, by a distribution nozzle (), on the first contact surface (), the adhesive composite (), and (iii) distributing, by a conductive spreader (), the adhesive composite (). The present disclosure further relates to a method to determine electrical resistance of an solder-reinforced adhesive between a first substrate () and a second substrate (), comprising (i) applying, by a distribution nozzle (), on a first contact surface () of the first substrate (), an adhesive composite () including, an adhesive () and a plurality of solder balls (), (ii) positioning, to a portion of the adhesive composite () opposite the first contact surface (), a second contact surface () of the second substrate (), (iii) attaching, to the first substrate () and the second substrate (), at least one electrical resistance detector (), and (iv) applying, to the first substrate () and the second substrate (), an electrical current. 1110. A method , to distribute a solder-reinforced adhesive on a first substrate () , comprising:{'b': 205', '115', '110', '200, 'applying, by a first distribution nozzle (), on a first contact surface () of a first substrate (), an adhesive ();'}{'b': 205', '300', '300', '200, 'applying, by a second distribution nozzle (), a plurality of solder balls (), such that at least one of the plurality of solder balls () is within the adhesive (); and'}{'b': 520', '300', '300', '115, 'distributing, by a conductive spreader (), the plurality of solder balls (), such that at least one of the plurality of solder balls () is in contact with the first contact surface ().'}2520212115300200. The method of claim 1 , wherein the conductive spreader () traverses ...

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Номер записи: 46
03-08-2017 дата публикации

SYSTEMS AND METHODS FOR REINFORCED ADHESIVE BONDING

Номер: US20170216947A1
Автор: Carlson Blair E., Li Yongqiang, WANG JIANFENG, YANG XIN
Принадлежит:

A solder-reinforced bonding system comprises a first substrate (), a second substrate () at least partially in contact with a heating element (), an adhesive () in contact with a first contact surface () of the first substrate () and a second contact surface () of the second substrate (), and a plurality of solder balls () positioned in the adhesive () in contact with the first contact surface () in a location to receive thermal energy from the heating element (). A method of producing a solder-reinforced adhesive bond between a first substrate () and second substrate (), comprises (i) applying an adhesive composite () including an adhesive () and a plurality of solder balls () on a first contact surface () of the first substrate (), (ii) connecting a second contact surface () of the second substrate () to a portion of the adhesive composite () opposite the first contact surface (), and (iii) applying thermal energy from a heating element (). 1100. A bonding system () , comprising:{'b': '110', 'a first substrate ();'}{'b': 120', '400, 'a second substrate (), at least partially in contact with a heating element ();'}{'b': 200', '115', '110', '125', '120, 'an adhesive (), in contact with a first contact surface (), of the first substrate (), and a second contact surface (), of the second substrate (); and'}{'b': 300', '200', '115', '400, 'a plurality of solder balls () positioned in the adhesive () in contact with the first contact surface () in a location to receive thermal energy from the heating element ().'}2400120. The system of claim 1 , wherein the heating element () produces thermal energy to a localized area of the second substrate ().3300110400. The system of claim 1 , wherein the plurality of solder balls ()bonds to the first substrate () at a temperature conductive to thermal energy produced by the heating element ().4300110400. The system of claim 1 , wherein at least one of plurality of solder balls () bonds to the first substrate () at a temperature ...

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Номер записи: 47
20-08-2015 дата публикации

ELECTRODE FOR RESISTANCE SPOT WELDING OF DISSIMILAR METALS

Номер: US20150231729A1
Автор: Carlson Blair E., Karagoulis Michael J., Schroth James G., Sigler David R., Yang David S.
Принадлежит: GM GLOBAL TECHNOLOGY OPERATIONS LLC

A method of spot welding a workpiece stack-up that includes a steel workpiece and an aluminum alloy workpiece involves passing an electrical current through the workpieces and between welding electrodes that are constructed to affect the current density of the electrical current. The welding electrodes, more specifically, are constructed to render the density of the electrical current greater in the steel workpiece than in the aluminum alloy workpiece. This difference in current densities can be accomplished by passing, at least initially, the electrical current between a weld face of the welding electrode in contact with the steel workpiece and a perimeter region of a weld face of the welding electrode in contact with the aluminum alloy workpiece. 1. A method of spot welding a workpiece stack-up that includes a steel workpiece and an aluminum alloy workpiece , the method comprising:providing a stack-up that includes a steel workpiece and an aluminum alloy workpiece that overlap to provide a faying interface;contacting a weld face of a steel welding electrode with a surface of the steel workpiece;contacting a weld face of an aluminum alloy welding electrode with a surface of the aluminum alloy workpiece, the weld face of the aluminum alloy welding electrode comprising a depression and a perimeter region surrounding the depression; andpassing an electrical current between the steel welding electrode and the aluminum alloy welding electrode, the electrical current at least initially passing through the perimeter region of the aluminum alloy welding electrode such that the welding current has a greater current density in the steel workpiece than in the aluminum alloy workpiece.2. The method set forth in claim 1 , wherein the perimeter region of the weld face of the aluminum alloy welding electrode comprises an annular perimeter base surface that surrounds and delimits the depression.3. The method set forth in claim 2 , wherein the depression is defined by a bottom and ...

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Номер записи: 48
10-08-2017 дата публикации

WELDING ELECTRODE CUTTING TOOL AND METHOD OF USING THE SAME

Номер: US20170225262A1
Автор: Carlson Blair E., Karagoulis Michael J., Sigler David R.
Принадлежит:

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. 1. A cutting tool capable of dressing asymmetric weld face geometries of first and second welding electrodes , the cutting tool comprising:a body having a first end and a second end, the first end of the body having a first opening and the second end of the body having a second opening; anda cutting member within the body, the cutting member having one or more cutting flutes, each of the one or more cutting flutes extending inwardly from an interior surface of the body and comprising a cutting blade that has axially spaced apart and opposed first and second shearing surfaces, the one or more cutting flutes establishing a first cutting socket, which is defined by the first shearing surfaces(s) and accessible through the first opening of the body, and a second cutting socket, which is defined by the second shearing surface(s) and accessible through the second opening of the body, the first cutting socket being constructed to cut a first weld face geometry into a weld face of a first welding electrode and the second cutting socket being constructed to cut a second weld face geometry into a weld face of a second welding electrode ...

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Номер записи: 49
10-08-2017 дата публикации

WELDING ELECTRODE CUTTING TOOL AND METHOD OF USING THE SAME

Номер: US20170225263A1
Автор: Carlson Blair E., Karagoulis Michael J., Schroth James G., Sigler David R.
Принадлежит:

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. 1. A cutting tool capable of dressing asymmetric weld face geometries of first and second welding electrodes , the cutting tool comprising:a body having a first end and a second end, the first end of the body having a first opening and the second end of the body having a second opening; anda cutting member within the body, the cutting member having one or more cutting flutes, each of the one or more cutting flutes extending inwardly from an interior surface of the body and comprising a cutting blade that has axially spaced apart and opposed first and second shearing surfaces, the one or more cutting flutes establishing a first cutting socket, which is defined by the first shearing surfaces(s) and accessible through the first opening of the body, and a second cutting socket, which is defined by the second shearing surface(s) and accessible through the second opening of the body, the first cutting socket being constructed to cut a first weld face geometry into a weld face of a first welding electrode and the second cutting socket being constructed to cut a second weld face geometry into a weld face of a second welding electrode ...

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Номер записи: 50
17-08-2017 дата публикации

JOINING OF LIGHT METAL ALLOY WORKPIECES TO STEEL WORKPIECES USING RESISTANCE SPOT WELDING AND ADHESIVE

Номер: US20170232548A1
Автор: Carlson Blair E., Sigler David R.
Принадлежит:

A method of adhesive weld bonding a light metal workpiece and a steel workpiece is disclosed that includes applying a plurality of discrete adhesive ribbons to a faying surface of the light metal workpiece, the faying surface of the steel workpiece, or both faying surfaces, and then assembling the workpieces together to establish one or more adhesive zones between the faying surfaces of the light metal and steel workpieces and a plurality of adhesive free zones amongst the adhesive zone(s). The method further includes forming a resistance spot weld that bonds the the light metal workpiece and the steel workpiece together at a spot weld location within one of the adhesive free zones. The formed spot weld includes a weld joint contained within the light metal workpiece that bonds to the faying interface of the steel workpiece. 1. A method of adhesive weld bonding a light metal workpiece and a steel workpiece together , the method comprising:providing a light metal workpiece having a faying surface and a steel workpiece having a faying surface;applying a plurality of discrete adhesive ribbons to the faying surface of the light metal workpiece, the faying surface of steel workpiece, or the faying surfaces of both the light metal workpiece and the steel workpiece;assembling the light metal workpiece and the steel workpiece together in overlapping fashion such that their faying surfaces establish a faying interface and, wherein, during such assembly, the discrete adhesive ribbons are spread out laterally between the faying surface of the light metal workpiece and the faying surface of the steel workpiece so that a plurality of adhesive free zones are established amongst one or more adhesive zones;forming a resistance spot weld that bonds the light metal workpiece and the steel workpiece together at a spot weld location within one of the adhesive free zones, the spot weld comprising a weld joint contained within the light metal workpiece that bonds to the faying interface ...

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Номер записи: 51
07-09-2017 дата публикации

MATING ELECTRODES FOR RESISTANCE SPOT WELDING OF ALUMINUM WORKPIECES TO STEEL WORKPIECES

Номер: US20170252853A1
Автор: Carlson Blair E., Karagoulis Michael J., Sigler David R., WANG Hui-Ping
Принадлежит:

A spot weld may be formed between an aluminum workpiece and an adjacent overlapping steel workpiece with the use of opposed spot welding electrodes that have mating weld faces designed for engagement with the outer surfaces of the workpiece stack-up assembly. The electrode that engages the stack-up assembly proximate the aluminum workpiece includes a central ascending convex surface and the electrode that engages the stack-up assembly proximate the steel workpiece has an annular surface. The mating weld faces of the first and second spot welding electrodes distribute the passing electrical current along a radially outwardly expanding flow path to provide a more uniform temperature distribution over the intended spot weld interface and may also produce a deformed bonding interface within the formed weld joint. Each of these events can beneficially affect the strength of the weld joint. 1. A method of forming a resistance spot weld in a workpiece stack-up assembly that includes a steel workpiece and an adjacent overlapping aluminum workpiece , the method comprising:providing a workpiece stack-up assembly that comprises a steel workpiece and adjacent aluminum workpiece that overlaps with the steel workpiece to establish a faying interface therebetween, the workpiece stack-up assembly having a first outer surface proximate the aluminum workpiece and an opposed second outer surface proximate the steel workpiece;pressing a first spot welding electrode against the first outer surface of the workpiece stack-up assembly, the first spot welding electrode comprising a weld face that includes a central ascending convex surface that rises above an annular surface that surrounds the central ascending convex surface, wherein, at least initially, the central ascending convex surface makes contact with the first outer surface of the workpiece stack-up assembly and the surrounding annular surface of the weld face of the first welding electrode does not;pressing a second spot welding ...

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Номер записи: 52
13-09-2018 дата публикации

MULTI-STEP DIRECT WELDING OF AN ALUMINUM-BASED WORKPIECE TO A STEEL WORKPIECE

Номер: US20180257166A1
Автор: Carlson Blair E., Karagoulis Michael J., Myasnikova Yelena, Sigler David R.
Принадлежит:

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. 1. A method of resistance spot welding a workpiece stack-up , which includes an aluminum-based workpiece and a steel workpiece , so as to form a resistance spot weld joint between the aluminum-based workpiece and the steel workpiece , the method comprising:contacting a workpiece stack-up with a pair of spot welding electrodes such that the spot welding electrodes make contact with opposed sides of the workpiece stack-up, the workpiece stack-up comprising an aluminum-based workpiece and a steel workpiece, the aluminum-based workpiece having a faying surface and the steel workpiece having a faying surface, and wherein the faying surfaces of the aluminum-based workpiece and the steel workpiece overlap and confront one another; and passing electrical current through the aluminum-based workpiece and the steel workpiece for a first period of time to grow a molten weld pool within the aluminum-based workpiece;', 'reducing passage of electrical current or ceasing passage of electrical current through the aluminum-based workpiece and the steel workpiece for a second period of time after the first period of time to allow the molten weld pool to cool and solidify to establish a weld bond area adjacent with and joined to the faying surface of the steel workpiece;', 'passing electrical current through the aluminum-based workpiece and the steel workpiece for a third period of time after the second period of time to re-melt at least part of the weld bond area., 'controlling the passage of electrical current between the spot welding electrodes and through the aluminum-based workpiece and the steel workpiece to perform multiple stages of weld joint development that include2. The method set forth in claim 1 ...

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Номер записи: 53
11-12-2014 дата публикации

RESISTANCE SPOT WELDING OF STEEL TO PRE-COATED ALUMINUM

Номер: US20140360986A1
Автор: Abd Elhamid Mahmoud H., Carlson Blair E., Sigler David R.
Принадлежит: GM GLOBAL TECHNOLOGY OPERATIONS LLC

Resistance spot welding of a steel workpiece to an aluminum or an aluminum alloy workpiece can be facilitated by replacing the refractory aluminum oxide-based layer(s) on at least the faying surface of the aluminum or aluminum alloy workpiece with a protective coating that is more conducive to the spot welding process. The protective coating may be a metallic coating or a metal oxide conversion coating. In a preferred embodiment, the protective coating is a coating of zinc, tin, or an oxide of titanium, zirconium, chromium, or silicon. 1. A method of joining a steel workpiece to an aluminum or aluminum alloy workpiece by resistance spot welding , the method comprising:providing an aluminum or an aluminum alloy workpiece that includes a faying surface and an electrode-contacting surface, wherein at least the faying surface has one or more aluminum oxide-based layers that overlie a bulk aluminum or aluminum alloy base substrate;replacing at least part of the aluminum oxide-based layer(s) at the faying surface of the aluminum or aluminum alloy workpiece with a protective coating, the protective coating being (1) a metal coating that has a lower melting point than that of aluminum or (2) a metal oxide conversion coating;overlapping the faying surface of the aluminum or aluminum alloy workpiece with a faying surface of a steel workpiece to form a faying interface between the workpieces in which the protective coating of the faying surface of the aluminum or aluminum alloy workpiece is present at a weld site;passing an electrical current through the workpieces and across the faying interface at the weld site to initiate and grow a molten weld pool within the aluminum or aluminum alloy workpiece that wets an adjacent surface of the steel workpiece; andallowing the molten weld pool within the aluminum or aluminum alloy workpiece to solidify into a weld joint.2. The method set forth in claim 1 , wherein the protective coating is a coating of tin.3. The method set forth in ...

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Номер записи: 54
29-09-2016 дата публикации

RESISTIVE WELDING ELECTRODE AND METHOD FOR SPOT WELDING STEEL AND ALUMINUM ALLOY WORKPIECES WITH THE RESISTIVE WELDING ELECTRODE

Номер: US20160279732A1
Автор: Carlson Blair E., Karagoulis Michael J., Kelly David P., Sigler David R.
Принадлежит:

A resistive welding electrode includes at least a weld face constructed of a refractory-based material that exhibits an electrical conductivity that is less than or equal to 65% of the electrical conductivity of commercially pure annealed copper as defined by the International Annealed Copper Standard (IACS). A method of using the resistive welding electrode to resistance spot weld a workpiece stack-up that includes an aluminum alloy workpiece and steel workpiece that overlap and contact each other at a faying interface is also disclosed. 1. A resistive welding electrode comprising:an electrode body; and{'sup': '7', 'a weld face disposed on a front end of the electrode body, and wherein at least the weld face is composed of a refractory-based material that includes at least 35 wt % of a refractory metal and has an electrical conductivity that is less than or equal to 3.8×10S/m.'}2. The resistive welding electrode set forth in claim 1 , wherein the refractory-based material is elemental molybdenum or elemental tungsten.3. The resistive welding electrode set forth in claim 1 , wherein the refractory-based material is a metal composite that includes 35 wt % or greater of molybdenum or tungsten.4. The resistive welding electrode set forth in claim 3 , wherein the refractory-based material is a tungsten-copper metal composite that comprise 50 wt % to 90 wt % of a tungsten particulate phase dispersed in a copper matrix.5. The resistive welding electrode set forth in claim 1 , wherein the weld face has a base weld face surface having a diameter that ranges from 6 mm to 20 mm and a spherical radius of curvature ranging from 15 mm to 300 mm.6. The resistive welding electrode set forth in claim 5 , wherein the weld face includes a plurality of upstanding claim 5 , radially-spaced circular ridges that surround a center of the weld face and project outwardly from the base weld face surface.7. The resistive welding electrode set forth in claim 1 , wherein the electrode body and ...

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Номер записи: 55
29-08-2019 дата публикации

IMPROVING MECHANICAL PERFORMANCE OF AL-STEEL WELD JOINTS BY LIMITING STEEL SHEET DEFORMATION

Номер: US20190262930A1
Автор: Carlson Blair E., Haselhuhn Amberlee S., Sigler David R.
Принадлежит:

A method of resistance spot welding a workpiece stack-up that includes a steel workpiece and one or more aluminum workpieces involves locally stiffening the steel workpiece to resist steel workpiece deformation. The local stiffening of the steel workpiece is achieved by incorporating an electrode receiving wall into the steel workpiece along with one or more integral elevated portions of the steel workpiece that are disposed at least partially around the electrode receiving wall. The electrode receiving wall includes an electrode-contact surface and an opposed interface contact surface. During welding, a weld face of one welding electrode is pressed against the electrode-contact surface of the electrode receiving wall of the steel workpiece, and electric current is momentarily passed between that welding electrode and another welding electrode on the opposite side of the workpiece stack-up to form a weld joint that bonds to the interface contact surface of the electrode receiving wall. 1. A method of resistance spot welding a workpiece stack-up that includes a steel workpiece and at least one adjacent overlapping aluminum workpiece , the method comprising:forming an electrode receiving wall in a steel workpiece, the electrode receiving wall having an electrode-contact surface and an opposed interface contact surface, the electrode-contact surface being at least partially defined by one or more integral elevated portions of the steel workpiece that protrude upwardly from the electrode-contact surface;assembling the steel workpiece and one or more aluminum workpieces in overlapping fashion to form a workpiece stack-up such that the interface contact surface of the electrode receiving wall of the steel workpiece confronts and makes contact with an adjacent faying surface of the one or more aluminum workpieces to establish a faying interface;pressing a first weld face of a first welding electrode against the electrode-contact surface of the electrode receiving wall of ...

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Номер записи: 56
27-09-2018 дата публикации

ELECTRODE FOR RESISTANCE SPOT WELDING OF DISSIMILAR MATERIALS

Номер: US20180272457A1
Автор: Carlson Blair E., Karagoulis Michael J., Schroth James G., Sigler David R., Yang David
Принадлежит:

A method of spot welding a workpiece stack-up that includes a steel workpiece and an aluminum alloy workpiece involves passing an electrical current through the workpieces and between welding electrodes that are constructed to affect the current density of the electrical current. The welding electrodes, more specifically, are constructed to render the density of the electrical current greater in the steel workpiece than in the aluminum alloy workpiece. This difference in current densities can be accomplished by passing, at least initially, the electrical current between a weld face of the welding electrode in contact with the steel workpiece and a perimeter region of a weld face of the welding electrode in contact with the aluminum alloy workpiece. 1. A spot-welded workpiece stack-up that includes a steel workpiece and an aluminum alloy workpiece that are joined together by at least one weld joint , the stack-up comprising:a steel workpiece that has an indented contact patch on an electrode-contacting surface thereof;an aluminum alloy workpiece that overlaps the steel workpiece to provide a faying interface, the aluminum alloy workpiece having an indented contact patch in an electrode-contacting surface thereof, the indented contact patch extending into the aluminum alloy workpiece and having a bulge therein; andat least one weld joint at the faying interface of the steel and aluminum alloy workpieces between the contact patch on the steel workpiece and the contact patch on the aluminum alloy workpiece, the weld joint metallurgically joining the steel and aluminum alloy workpieces together.2. The spot-welded workpiece stack-up set forth in claim 1 , wherein the weld joint comprises an aluminum alloy weld nugget and a Fe—Al intermetallic layer between the aluminum alloy weld nugget and the steel workpiece.3. The spot-welded workpiece stack-up set forth in claim 2 , wherein the Fe—Al intermetallic layer has a thickness of about 1 μm to about 3 μm at least underneath ...

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Номер записи: 57
06-10-2016 дата публикации

CONICAL SHAPED CURRENT FLOW TO FACILITATE DISSIMILAR METAL SPOT WELDING

Номер: US20160288242A1
Автор: Carlson Blair E., Sigler David R.
Принадлежит:

A method of resistance spot welding a workpiece stack-up that includes a steel workpieces and an aluminum alloy workpiece that overlie and contact one another to establish a faying interface at a weld site is disclosed. The method comprises passing a DC electrical current through the workpiece stack-up at the weld site and causing the current to assume a conical flow pattern. The conical flow pattern has a path of current flow that expands along a direction leading from a first welding electrode in electrical communication with the steel workpiece towards a second welding electrode in electrical communication with the aluminum alloy workpiece. 1. A method of resistance spot welding a workpiece stack-up that includes steel workpiece and an aluminum alloy workpiece; the method comprising:providing a workpiece stack-up that includes a steel workpiece and an aluminum alloy workpiece, the steel workpiece having a faying surface that overlies and contacts a faying surface of the aluminum alloy workpiece to establish a faying interface at a weld site;bringing a first welding electrode into electrical communication with the steel workpiece at the weld site;bringing a second welding electrode into electrical communication with the aluminum alloy workpiece at the weld site;passing a DC electrical current through the workpiece stack-up at the weld site and between the first and second welding electrodes to initiate and grow a molten aluminum alloy weld pool within the aluminum alloy workpiece, the DC electrical current assuming a conical flow pattern in which a path of current flow expands radially along a direction leading from the first welding electrode towards the second welding electrode such that a current density of the DC electrical current decreases along the direction within at least a portion of the workpiece stack-up spanning from within the steel workpiece, across the faying interface, and into the aluminum alloy workpiece.2. The method set forth in claim 1 , ...

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Номер записи: 58
04-10-2018 дата публикации

ADDITIVE MANUFACTURING WITH LASER ENERGY RECYCLING

Номер: US20180281065A1
Автор: Carlson Blair E., CHAE HYUNGMIN, Nolte Jason J., Perry Thomas A., Spicer John Patrick
Принадлежит: GM GLOBAL TECHNOLOGY OPERATIONS LLC

Additive manufacturing systems, area scanning laser systems, and methods for performing an additive manufacturing process are provided. An exemplary additive manufacturing system includes a laser generation device for producing a laser beam. Further, the additive manufacturing system includes an optic element for forming a first portion of the laser beam with a first polarization and a second portion of the laser beam with a second polarization different from the first polarization to encode an image in the laser beam. Also, the additive manufacturing system includes a selective beam separator configured to direct the first portion of the laser beam onto a material to be sintered or melted. The additive manufacturing system includes a recycling system for receiving the second portion of the laser beam. 1. An additive manufacturing system comprising:a laser generation device for producing a laser beam;an optic element for forming a first portion of the laser beam with a first polarization and a second portion of the laser beam with a second polarization different from the first polarization to encode an image in the laser beam;a selective beam separator configured to direct the first portion of the laser beam onto a material to be sintered or melted; anda recycling system for receiving the second portion of the laser beam.2. The additive manufacturing system of wherein the recycling system is configured to convert radiant energy of the second portion of the laser beam into electric energy.3. The additive manufacturing system of wherein the recycling system comprises a thermoelectric generator configured to convert energy from the laser beam to electric energy.4. The additive manufacturing system of wherein the recycling system comprises:a thermoelectric generator configured to convert energy from the laser beam to electric energy; andan inverter coupled to the thermoelectric generator.5. The additive manufacturing system of wherein the recycling system comprises:a ...

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Номер записи: 59
04-10-2018 дата публикации

SOLDER ADHESIVE FOR JOINING OF BATTERY TABS

Номер: US20180281093A1
Автор: Carlson Blair E., Sekol Ryan C., WANG Hui-Ping
Принадлежит: GM GLOBAL TECHNOLOGY OPERATIONS LLC

A method of manufacturing a battery module includes applying an adhesive solder to a tab of a battery cell. The adhesive solder includes a mixture of an adhesive composition and a plurality of solder elements. The adhesive solder is compressed between the tab of the first battery cell and an electrically conductive element, such as a tab of a second battery cell or a bus plate. The adhesive solder is then heated, whereby the adhesive composition is cured to fixedly attach the tab of the first battery cell and the electrically conductive element together, and the plurality of solder elements bond with the tab of the first battery cell and the electrically conductive element to connect them in electrical communication. 1. A method of manufacturing a battery module , the method comprising:applying an adhesive solder to a tab of a first battery cell, wherein the adhesive solder includes a mixture of an adhesive composition and a plurality of solder elements;compressing the adhesive solder between the tab of the first battery cell and an electrically conductive element;curing the adhesive solder, whereby the tab of the first battery cell and the electrically conductive element are fixedly attached to each other by the adhesive composition, and the tab of the first battery cell and the electrically conductive element are electrically connected to each other by the plurality of solder elements.2. The method set forth in claim 1 , wherein the tab of the first battery cell and the electrically conductive element are not welded together.3. The method set forth in claim 1 , wherein the electrically conductive element includes at least one of a tab of a second battery cell or a bus plate.4. The method set forth in claim 1 , wherein curing the adhesive solder includes heating the adhesive solder to a temperature equal to or less than a predetermined maximum temperature claim 1 , for a time period equal to or less than a predefined maximum time period.5. The method set forth in ...

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Номер записи: 60
19-09-2019 дата публикации

RESISTANCE SPOT WELDING WORKPIECE STACK-UPS HAVING A STEEL WORKPIECE AND AN ALUMINUM WORKPIECE WITH A STEEL PLATE

Номер: US20190283168A1
Автор: Carlson Blair E., Jensen Charles E., Sigler David R.
Принадлежит:

A method of resistance spot welding a workpiece stack-up. The workpiece stack-up includes at least a steel workpiece and an aluminum workpiece. The method involves attaching a steel plate to the steel workpiece at a weld-site of the workpiece stack-up, passing electrical current between a first welding electrode and a second welding electrode at the weld-site, and terminating passage of electrical current between the first and second welding electrodes in order to form a weld joint. The steel plate serves to stiffen the weld joint. 1. A method of resistance spot welding a workpiece stack-up that comprises a steel workpiece and an aluminum workpiece , the method comprising:attaching a steel plate to the steel workpiece at a weld-site of the workpiece stack-up;clamping a first welding electrode and a second welding electrode on the workpiece stack-up at the weld-site;passing electrical current between the first and second welding electrodes at the weld-site to create a molten aluminum weld pool within the aluminum workpiece that wets a faying surface of the steel workpiece; andterminating passage of electrical current between the first and second welding electrodes to allow the molten aluminum weld pool to solidify into a weld joint;wherein the steel plate stiffens the weld joint that bonds the steel and aluminum workpieces together.2. The method set forth in claim 1 , wherein attaching the steel plate to the steel workpiece involves applying adhesive between the steel plate and the steel workpiece.3. The method set forth in claim 1 , wherein attaching the steel plate to the steel workpiece involves resistance spot welding the steel plate to the steel workpiece.4. The method set forth in claim 1 , wherein attaching the steel plate to the steel workpiece involves applying adhesive between the steel plate and the steel workpiece claim 1 , subsequently performing the step of clamping the first and second welding electrodes on the workpiece stack-up and the steel plate at ...

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Номер записи: 61
19-10-2017 дата публикации

RESISTANCE SPOT WELDING STEEL AND ALUMINUM WORKPIECES WITH ELECTRODE HAVING INSERT

Номер: US20170297135A1
Автор: Carlson Blair E., Sachdev Anil K., Schroth James G., Sigler David R., Yang David S.
Принадлежит:

A method of resistance spot welding a steel workpiece and an aluminum or aluminum alloy workpiece, and a welding electrode used therein. In one step of the method a workpiece stack-up is provided. The workpiece stack-up includes a steel workpiece and an aluminum or aluminum alloy workpiece. Another step of the method involves contacting the aluminum or aluminum alloy workpiece with a weld face of the welding electrode. The welding electrode has a body and an insert. The insert is composed of a material having an electrical resistivity that is greater than an electrical resistivity of the material of the body. The weld face has a first section defined by a surface of the insert and has a second section defined by a surface of the body. Both the first and second sections make surface-to-surface contact with the aluminum or aluminum alloy workpiece amid resistance spot welding. 1. A method of resistance spot welding a steel workpiece and an aluminum or aluminum alloy workpiece , the method comprising:providing a workpiece stack-up that includes a steel workpiece and an aluminum or aluminum alloy workpiece;contacting the aluminum or aluminum alloy workpiece with a first weld face of a first welding electrode, the first welding electrode having a body and an insert, the body composed of a first material and the insert composed of a second material, the second material having an electrical resistivity that is greater than an electrical resistivity of the first material, the first weld face having a first section defined by a surface of the insert and having a second section defined by a surface of the body, the first and second sections making surface-to-surface contact with the aluminum or aluminum alloy workpiece;contacting the steel workpiece with a second weld face of a second welding electrode; andpassing a DC electrical current between the first welding electrode and the second welding electrode.2. The method as set forth in claim 1 , wherein the second material of ...

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Номер записи: 62
19-10-2017 дата публикации

CONTROL OF INTERMETALLIC COMPOUND GROWTH IN ALUMINUM TO STEEL RESISTANCE WELDING

Номер: US20170297136A1
Автор: Brown Tyson W., Carlson Blair E., Haselhuhn Amberlee S., Sigler David R.
Принадлежит:

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. 1. A method of resistance spot welding a workpiece stack-up that includes an aluminum workpiece and an adjacent overlapping steel workpiece so as to minimize the thickness of an intermetallic layer comprising Fe—Al intermetallic compounds , the method comprising:providing a workpiece stack-up that has an accessible first side and an opposed accessible second side, the workpiece stack-up comprising an aluminum workpiece and an overlapping adjacent steel workpiece and further comprising one or more reaction-slowing elements at a faying interface established between the aluminum and steel workpieces, the reaction-slowing elements comprising at least one of carbon, copper, silicon, nickel, manganese, cobalt, or chromium;pressing a weld face of a first welding electrode against the first side of the workpiece stack-up and pressing a weld face of a second welding electrode against the second side of the workpiece stack-up in facial alignment with the weld face of the first welding electrode;passing an ...

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Номер записи: 63
19-10-2017 дата публикации

RESISTANCE SPOT WELDING OF ALUMINUM-TO-ALUMINUM, ALUMINUM-TO-STEEL, AND STEEL-TO- STEEL IN A SPECIFIED SEQUENCE AND USING A COVER

Номер: US20170297138A1
Автор: Carlson Blair E., Karagoulis Michael J., Sigler David R.
Принадлежит:

A series of many electrical resistance spot welds is to be formed in members of an assembled, but un-joined, body that presents workpiece stack-ups of various combinations of metal workpieces including all aluminum workpieces, all steel workpieces, and a combination of aluminum and steel workpieces. A pair of spot welding electrodes, each with a specified weld face that includes oxide-disrupting features, is used to form the required numbers of aluminum-to-aluminum spot welds, aluminum-to-steel spot welds, and steel-to-steel spot welds. A predetermined sequence of forming the various spot welds may be specified for extending the number of spot welds that can be made before the weld faces must be restored. And, during at least one of the aluminum-to-steel spot welds, a cover is inserted between the weld face of one of the welding electrodes and a side of a workpiece stack-up that includes the adjacent aluminum and steel workpieces. 1. A method of resistance spot welding workpiece stack-ups of different combinations of metal workpieces with a single weld gun using the same set of welding electrodes , the method comprising:providing a weld gun that carries a set of opposed welding electrodes, each of the opposed welding electrodes having a weld face that comprises oxide-disrupting structural features;forming a set of aluminum-to-aluminum spot welds, each of the aluminum-to-aluminum spot welds comprising an aluminum nugget that fusion welds two or more aluminum workpieces together;forming a set of aluminum-to-steel spot welds, each of the aluminum-to-steel spot welds comprising a weld joint contained within an aluminum workpiece that weld bonds the aluminum workpiece to an adjacent steel workpiece, and wherein forming at least one of the set of aluminum-to-steel spot welds comprises inserting a cover between a weld face of one of the opposed welding electrodes and a side of a workpiece stack-up that includes the aluminum workpiece and the adjacent steel workpiece to ...

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Номер записи: 64
26-10-2017 дата публикации

Alternately direct resistance spot welding of al-to-al, al-to-steel, and steel-t0-steel with welding electrode having oxide-disrupting structural features

Номер: US20170304928A1
Автор: Blair E. Carlson, David R. Sigler, Michael J. Karagoulis
Принадлежит: GM GLOBAL TECHNOLOGY OPERATIONS LLC

A method of resistance spot welding workpiece stack-ups of different combinations of metal workpieces with a single weld gun using the same set of welding electrodes is disclosed. In this method, a set of opposed welding electrodes that include an original shape and oxide-disrupting structural features are used to resistance spot weld at least two of the following types of workpiece stack-ups in a particular sequence: (1) a workpiece stack-up of two or more aluminum workpieces; (2) a workpiece stack-up that includes an aluminum workpiece and an adjacent steel workpiece; and (3) a workpiece stack-up of two or more steel workpieces. The spot welding sequence calls for completing all of the aluminum-to-aluminum spot welds and/or all of the steel-to-steel spot welds last.

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Номер записи: 65
26-10-2017 дата публикации

FRICTION STIR WELDING BOBBIN TOOL

Номер: US20170304934A1
Автор: Carlson Blair E., Hovanski Yuri, MELLAS Spyros P., Ross Kenneth, Szymanski Robert T.
Принадлежит:

A bobbin tool is disclosed that includes a top shoulder, a bottom shoulder, and an axial pin that extends between the top and bottom shoulders. The bottom shoulder has an annular shoulder end surface, a back surface opposite the annular shoulder end surface, and a side surface that joins the annular shoulder end surface and the back surface. One or more and radially-extending blades may be disposed on the side surface of the bottom shoulder and/or one or more axially-extending blades may be disposed on the back surface. The one or more blades provide the bobbin tool with an ability to friction stir weld a variable thickness workpiece assembly, axially plunged through the workpiece assembly along an axis of rotation of the bobbin tool, and/or be extracted through the workpiece assembly along an axis of rotation of the bobbin tool. 1. A bobbin tool for friction stir welding , the bobbin tool comprising:a top shoulder having an annular shoulder end surface;a bottom shoulder having an annular shoulder end surface, a back surface opposite the annular shoulder end surface of the bottom shoulder, and a side surface that joins the annular shoulder end surface and the back surface of the bottom shoulder, the annular shoulder end surface of bottom shoulder being spaced from and facing the annular shoulder end surface of the top shoulder to define a gap between the annular shoulder end surface of the top shoulder and the annular shoulder end surface of the bottom shoulder;an axial pin that extends between the top shoulder and the bottom shoulder along an axis of rotation of the bobbin tool and through the gap defined by the annular shoulder end surface of the top shoulder and the annular shoulder end surface of the bottom shoulder; andone or more blades disposed on the bottom shoulder, wherein the one or more blades includes at least one blade that extends radially outwardly from the side surface of the bottom shoulder or that extends axially from the bottom surface of the ...

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Номер записи: 66
17-09-2020 дата публикации

COMPOSITE FUSION FILAMENT

Номер: US20200290269A1
Автор: Carlson Blair E., Gergely Ryan, Okonski David A., Rodgers William R.
Принадлежит:

A composite fusion filament is disclosed that includes a polymer encasement and one or more mesogenic reinforcement bodies contained within the polymer encasement. The polymer encasement is comprised of a thermoplastic polymer, which has a melting temperature, and each of the one or more mesogenic reinforcement bodies is comprised of a thermotropic liquid crystal polymer, which has a clearing temperature. The melting temperature of the thermoplastic polymer included in the polymer encasement is less than the clearing temperature of the thermotropic liquid crystal polymer included in the one or more mesogenic reinforcement bodies. Additionally, the thermotropic liquid crystal polymer of each mesogenic reinforcement body has a plurality of organized crystalline fibrils that are aligned lengthwise along a longitudinal axis of the polymer encasement. A method of using the composite fusion filament to form a bond with a substrate that includes a thermoplastic polymer is also disclosed.

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Номер записи: 67
17-09-2020 дата публикации

FILAMENT DEPOSITION HEAD AND METHOD OF DEPOSITING FILAMENT MATERIAL FOR JOINING WORKPIECES

Номер: US20200290271A1
Автор: Carlson Blair E., Gergely Ryan, Okonski David A., Rodgers William R., Wells James W.
Принадлежит:

A fused filament deposition head is employed for depositing filament materials on workpieces to join the workpieces together. The workpieces can be of an automotive application, aerospace application, or something else. The fused filament deposition head, in an example, has a feed end, a dispensing end, and a heater. The feed end introduces more than one filament in the fused filament deposition head, as demanded in the larger application. The dispensing end delivers materials of the filaments to the underlying workpieces. The materials are delivered together. The heater serves to heat the filaments as they travel through the fused filament deposition head. The filaments can include a filament having a core portion of liquid-crystal polymer material.

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Номер записи: 68
17-09-2020 дата публикации

JOINING THERMOPLASTIC WORKPIECES WITH INDUCTION HEATING

Номер: US20200290290A1
Автор: Carlson Blair E., Gergely Ryan, Okonski David A.
Принадлежит:

A method of joining workpieces includes the steps of bringing a first workpiece and a second workpiece together, induction heating a susceptor material, and pressing the workpieces together. Each workpiece may include a thermoplastic material, and the workpieces are brought together at a joint interface so that a protrusion of the first workpiece is aligned with a receptacle of the second workpiece. The susceptor material is in contact with the thermoplastic material of the first workpiece during heating such that the thermoplastic material of the first workpiece softens. The step of pressing is performed while the thermoplastic material of the first workpiece is softened, thereby reshaping the first workpiece where the susceptor material is in contact with the thermoplastic material of the first workpiece. The protrusion is deformed to form an interlock with the receptacle at the joint interface.

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Номер записи: 69
01-11-2018 дата публикации

HIGH THROUGHPUT ADDITIVE MANUFACTURING SYSTEM

Номер: US20180311731A1
Автор: Carlson Blair E., CHAE HYUNGMIN, Nolte Jason J., Perry Thomas A., Sachdev Anil K., Smith Mark A., Spicer John P.
Принадлежит:

An additive manufacturing system has a powder delivery system for presenting a powder material to a build chamber. A laser selectively sinters the powder material in the build chamber. The build chamber is presented in an annular configuration with the powder delivery system and laser arranged within a central portion thereof. 1. An additive manufacturing system , comprising:a powder delivery system for providing a predetermined amount of a powder material to a build chamber;a laser for selectively sintering the powder material in the build chamber, wherein the build chamber is presented in an annular configuration with the powder delivery system and laser arranged within a central portion thereof.2. The additive manufacturing system of claim 1 , wherein the annular build chamber rotates under the powder delivery system and the laser.3. The additive manufacturing system of claim 2 , wherein the powder delivery system includes a material dispenser for dispensing the powder material and a scraper for removing excess material from the build chamber.4. The additive manufacturing system of claim 2 , wherein the build chamber has a fixed height and the powder delivery system and laser are vertically movable.5. The additive manufacturing system of claim 2 , wherein the powder delivery system and laser have a fixed height and the build chamber is vertically movable.6. The additive manufacturing system of claim 2 , wherein the laser moves in a raster pattern to sinter a layer of powder material to a directly preceding layer of powder material claim 2 , and wherein the layer of powder material is a different composition than the directly preceding layer of powder material7. The additive manufacturing system of claim 3 , wherein at least one of the build chamber claim 3 , the laser claim 3 , the material dispenser claim 3 , and the scraper is independently movable.8. The additive manufacturing system of claim 2 , wherein the build chamber is divided into a plurality of ...

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Номер записи: 70
01-11-2018 дата публикации

SYSTEMS AND METHODS FOR REINFORCED ADHESIVE BONDING USING TEXTURED SOLDER ELEMENTS

Номер: US20180315682A1
Автор: Carlson Blair E., Gao Dalong, Li Yongbing, YANG XIN
Принадлежит:

The present disclosure relates to a bonding system comprising a first substrate, a second substrate, an adhesive, in contact with a first contact surface and a second contact surface, and a plurality of solder elements positioned in the adhesive. Each solder element has a plurality of indentations located on the perimeter of the solder element and the plurality of indentations receiving a portion of the adhesive. Also, the present disclosure relates to a bonding method to produce a solder-reinforced adhesive bond joining a first substrate and a second substrate. 1. A bonding system , comprising:a first substrate;a second substrate;an adhesive, in contact with a first contact surface, of the first substrate, and a second contact surface, of the second substrate; anda plurality of solder elements positioned in the adhesive, wherein each solder element has a plurality of indentations located on a perimeter of the solder element and the plurality of indentations receiving a portion of the adhesive.2. The bonding system of claim 1 , wherein at least one of the plurality of solder elements is in contact with the first contact surface.3. The bonding system of claim 1 , wherein at least one of the plurality of solder elements is in contact with the first contact surface and the second contact surface.4. The bonding system of claim 1 , wherein each of the plurality of solder elements is generally spherical.5. The bonding system of claim 1 , wherein the plurality of solder elements are positioned within the adhesive to inhibit crack propagation or promote crack propagation along a path requiring claim 1 , in at least one section of the bonding system claim 1 , an amount of energy that is greater than a fracture energy needed to propagate a crack generally straight through a bond line of adhesive sans the plurality of solder elements.6. The bonding system of claim 1 , wherein the plurality of indentations on each solder element are spaced generally evenly around the perimeter ...

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Номер записи: 71
09-11-2017 дата публикации

ELECTROCHEMICAL TESTING FOR CORROSION ANALYSIS

Номер: US20170322144A1
Автор: Carlson Blair E., Maddela Surender
Принадлежит: GM GLOBAL TECHNOLOGY OPERATIONS LLC

A method for testing an electrochemical response of a sample, which is at least partially disposed within an electrolyte, includes macro scanning the sample. Macro scanning is applied across the entire sample and includes applying a first range of macro potential between the electrolyte and the sample, and measuring a first range of macro current between the electrolyte and the sample, while subject to the first range of macro potential. The macro scan is held at a first fixed macro potential within the first range of macro potential and the sample is micro scanned while held at the first fixed macro potential. Micro scanning is applied at individual points across a surface portion of the sample and includes measuring a plurality of first micro currents at each of the individual points of the surface portion of the sample. Each individual point is significantly smaller than the entire sample. 1. A test stand for testing electrochemical response of a sample , comprising:a test chamber;an electrolyte disposed within the test chamber, wherein the sample is configured to be at least partially disposed within the electrolyte; apply a first range of macro potential between the electrolyte and the entire sample, and measure a first range of macro current between the electrolyte and the entire sample, while subject to the first range of macro potential;', 'hold at a first fixed macro potential within the first range of macro potential;', 'apply a second range of macro potential between the electrolyte and the entire sample, and measure a second range of macro current between the electrolyte and the entire sample, while subject to the second range of macro potential; and', 'hold at a second fixed macro potential within the second range of macro potential;, 'a macro potentiostat, operatively connected to the sample and the electrolyte, and configured to measure a plurality of first micro currents at a plurality of individual points of the surface portion of the sample, while ...

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Номер записи: 72
01-12-2016 дата публикации

RESISTANCE SPOT WELDING WORKPIECE STACK-UPS OF DIFFERENT COMBINATIONS OF STEEL WORKPIECES AND ALUMINUM WORKPIECES

Номер: US20160346865A1
Автор: Carlson Blair E., Sigler David R., SMYTH SUSAN M., Spicer John Patrick
Принадлежит:

A method of resistance spot welding workpiece stack-ups of different combinations of steel workpieces and aluminum workpieces includes several steps. In one step, a workpiece stack-up is brought between a first weld gun arm and a second weld gun arm. The first weld gun arm includes a first welding electrode, and the second weld gun arm includes a carrier that supports a second welding electrode and a third welding electrode. Another step involves rotating the carrier and passing electrical current through the workpiece stack-up using the first welding electrode in conjunction with either the second welding electrode or the third welding electrode depending on which electrode has been rotated into facing alignment with the first welding electrode. 1. A method of resistance spot welding workpiece stack-ups of different combinations of steel workpieces and aluminum workpieces , the method comprising:providing a first workpiece stack-up that includes a pair of steel workpieces or a pair of aluminum workpieces, and providing a second workpiece stack-up that includes a steel workpiece and an aluminum workpiece;providing a first weld gun arm with a first welding electrode, and providing a second weld gun arm having a rotatable carrier that supports a second welding electrode and a third welding electrode;bringing the first workpiece stack-up between the first and second weld gun arms, and passing electrical current through the first workpiece stack-up and between the first welding electrode and the second welding electrode;rotating the carrier; andbringing the second workpiece stack-up between the first and second weld gun arms, and passing electrical current through the second workpiece stack-up and between the first welding electrode and the third welding electrode.2. The method as set forth in claim 1 , wherein the third welding electrode confronts the aluminum workpiece and is axially aligned with the first welding electrode when passing electrical current through the ...

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Номер записи: 73
10-12-2015 дата публикации

COVER PLATE WITH INTRUDING FEATURE TO IMPROVE AL-STEEL SPOT WELDING

Номер: US20150352659A1
Автор: Carlson Blair E., Sigler David R., WANG Hui-Ping, Yang David
Принадлежит:

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. 1. A method of spot welding a workpiece stack-up that includes a steel workpiece and an adjacent aluminum alloy workpiece , the method comprising:providing a workpiece stack-up that includes a steel workpiece and an aluminum alloy workpiece that overlaps and lies adjacent to the steel workpiece to establish a faying interface at a weld site, the workpiece stack-up having a first side and a second side, the first side of the workpiece stack-up being proximate the steel workpiece and the second side of the workpiece stack-up being proximate the aluminum alloy workpiece;locating a cover plate adjacent to the second side of the workpiece stack-up, the cover plate having an interior surface that confronts the second side of the workpiece stack-up and exterior surface that faces in an opposite direction from the interior surface, the cover plate further comprising an intruding feature aligned with the weld site;pressing a first weld face of a first welding electrode against the first side of the workpiece stack-up and pressing a second weld face of a second welding electrode against the exterior surface of the cover plate over the intruding feature, the first and second weld faces of the first and second welding electrodes being ...

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Номер записи: 74
08-12-2016 дата публикации

WELDING METHOD AND SYSTEM

Номер: US20160355902A1
Автор: Carlson Blair E., Sun Li, Yang David, Zhang Jing
Принадлежит: GM GLOBAL TECHNOLOGY OPERATIONS LLC

A welding method includes the following steps: (a) determining a martensite tempering temperature of the at least two workpieces based, at least in part, on the chemical composition and microstructure of the woworkpieces; (b) applying sufficient energy to the workpieces to melt the workpieces at a target location, thereby creating a weld pool; (c) determining, via the control module, a target temperature and cooling range of a coolant and cooling range based, at least in part, on the martensite tempering temperature and HAZ width; and (d) cooling the first and second workpieces with the coolant such that a temperature of the workpieces at heat-affected zones is controlled below the martensite tempering temperature in order to minimize softening at the heat-affected zones. The present invention also relates to a welding system for minimizing HAZ softening. 1. A welding method , comprising:determining, via a control module, a martensite tempering temperature of at least two workpieces based, at least in part, on a chemical composition of the at least two workpieces;applying sufficient energy to the at least two workpieces to melt the at least two workpieces at a target location, thereby creating a weld pool, the target location being located at an interference between the at least two workpieces;determining, via the control module, a target temperature of a coolant based, at least in part, on the martensite tempering temperature the at least two workpieces; andcooling the at least two workpieces with the coolant such that a temperature of the at least two workpieces at heat-affected zones is controlled below the martensite tempering temperature in order to minimize softening at the heat-affected zones, wherein each heat-affected zone is an area of the at least two workpieces around the weld pool subjected to heat stemming from the energy applied to the at least two workpieces at the target location.2. The welding method of claim 1 , wherein cooling the at least two ...

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Номер записи: 75
21-12-2017 дата публикации

MULTISTEP ELECTRODE WELD FACE GEOMETRY FOR WELD BONDING ALUMINUM TO STEEL

Номер: US20170361392A1
Автор: Carlson Blair E., Chen Nannan, Sigler David R., WANG Hui-Ping
Принадлежит:

A spot welding electrode and a method of using the electrode to resistance spot weld a workpiece stack-up that includes an aluminum workpiece and an adjacent overlapping steel workpiece are disclosed. The spot welding electrode includes a weld face having a multistep conical geometry that includes a series of steps centered on a weld face axis. The series of steps comprises an innermost first step in the form of a central plateau and, additionally, one or more annular steps that surround the central plateau and cascade radially outwardly from the central plateau towards an outer perimeter of the weld face. The weld face has a conical cross-sectional profile in which a periphery of a top plateau surface of the central plateau and a periphery of a top annular step surface of each of the one or more annular steps are contained within a conical sectional area. 1. A spot welding electrode comprising:a body;a weld face supported on an end of the body, the weld face having a multistep conical geometry that includes a series of steps centered on a weld face axis and contained within an outer perimeter of the weld face, the series of steps comprising an innermost first step in the form of a central plateau and, additionally, one or more annular steps that surround the central plateau and cascade radially outwardly from the central plateau towards the outer perimeter of the weld face, the central plateau having a top plateau surface and each of the one or more annular steps having a top annular step surface, wherein the weld face has a conical cross-sectional profile in which a periphery of the top plateau surface of the central plateau and a periphery of the top annular step surface of each of the one or more annular steps are contained within a conical sectional area defined by an upper linear boundary line and a lower linear boundary line that intersect at the periphery of the top plateau surface and extend downwardly and outwardly from a horizontal plane extending from ...

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Номер записи: 76
12-11-2020 дата публикации

MOLDING PROCESS FOR JOINING PREFABRICATED WORKPIECE SUBSTRATES INTO A WORKPIECE ASSEMBLY

Номер: US20200353656A1
Автор: Carlson Blair E., Gergely Ryan, Okonski David A., Rodgers William R.
Принадлежит:

A method of joining a first workpiece substrate and a second workpiece substrate is disclosed in which a local mold tool is positioned into contact with the first workpiece substrate and the second workpiece substrate. The local mold tool defines a mold cavity and encloses an edge portion of the first workpiece substrate and an edge portion of the second workpiece substrate such that the edge portion of the first workpiece substrate and the edge portion of the second workpiece substrate are contained within the mold cavity. Once the local mold tool is positioned, a liquid polymer molding compound is injected into the mold cavity. The liquid polymer molding compound is hardened in the mold cavity into a polymer joint that adheres the edge portion of the first workpiece substrate and the edge portion of the second workpiece substrate together. 1. A method of joining workpiece substrates to form a workpiece assembly , the method comprising:positioning a local mold tool into contact with a first workpiece substrate and a second workpiece substrate, the local mold tool defining a mold cavity in conjunction with the first and second workpiece substrates and further enclosing an edge portion of the first workpiece substrate and an edge portion of the second workpiece substrate such that the edge portion of the first workpiece substrate and the edge portion of the second workpiece substrate are contained within the mold cavity;injecting a liquid polymer molding compound into the mold cavity, the liquid polymer molding compound flowing through and filling the mold cavity and further contacting each of the edge portion of the first workpiece substrate and the edge portion of the second workpiece substrate; andhardening the liquid polymer molding compound into a polymer joint that adheres the edge portion of the first workpiece substrate and the edge portion of the second workpiece substrate together.2. The method set forth in claim 1 , wherein the liquid polymer molding ...

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Номер записи: 77
10-12-2020 дата публикации

Electromagnetic Probe To Detect Discontinuities In Metal Joints

Номер: US20200386714A1
Автор: Carlson Blair E., Haselhuhn Amberlee S., McGovern Megan E., Rinker Teresa J.
Принадлежит:

A probe for detecting discontinuities includes: a body portion; a head portion; one or more inductor coils located in the head portion and configured to: receive power from a power source; when power is received, induce an eddy current in a joint where a first metal component is joined with a second metal component; based on the induced eddy current, output a signal indicative of an inductance of the one or more inductor coils; and a plurality of positioning devices configured to maintain the one or more inductor coils approximately a predetermined distance from the surface. 1. A probe for detecting discontinuities , the probe comprising:a body portion;a head portion; receive power from a power source;', 'when power is received, induce an eddy current in a joint where a first metal component is joined with a second metal component;', 'based on the induced eddy current, output a signal indicative of an inductance of the one or more inductor coils; and, 'one or more inductor coils located in the head portion and configured toa plurality of positioning devices configured to maintain the one or more inductor coils approximately a predetermined distance from the surface.2. The probe of wherein the positioning devices include a plurality of extensions that extend only radially outwardly from the head portion.3. The probe of wherein the one or more inductor coils are located in one of the extensions.4. The probe of wherein the plurality of extensions include at least three extensions that extend only radially outwardly from the head portion claim 2 ,wherein the at least three separate extensions are located equidistantly around the head portion.5. The probe of wherein the plurality of extensions define a circle having a first diameter that is greater than a second diameter of the joint.6. The probe of wherein the joint includes a spot weld formed by resistance spot welding (RSW).7. The probe of further comprising a central portion that is rotatable within the body portion ...

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Номер записи: 78
25-12-2018 дата публикации

Methods and systems for reinforced adhesive bonding using solder elements and flux

Номер: US10160066B2
Автор: Blair E. Carlson, XIN YANG, Yongbing Li
Принадлежит: GM GLOBAL TECHNOLOGY OPERATIONS LLC

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.

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Номер записи: 79
29-05-2019 дата публикации

Method for producing a cast or molded part with an insert for receiving punch rivets

Номер: DE102012205357B4
Автор: Blair E. Carlson, Pei-Chung Wang
Принадлежит: GM GLOBAL TECHNOLOGY OPERATIONS LLC

Verfahren zum Einrichten eines Gieß- oder Formprozesses zur Erzeugung eines Gussteiles oder Formteiles, um einen Stanzniet (10) aufzunehmen und dadurch eine Verbindung zum Anbringen des Gussteiles oder Formteiles an einem Werkstück zu bilden, wobei das Gussteil oder der Formteil in einem durch ein oberes und ein unteres Formwerkzeug (66, 68) gebildeten Formhohlraum mit gegenüberliegenden Flächen gebildet und im Inneren einer Form angeordnet wird, wobei die obere der beiden gegenüberliegenden Flächen eine ebene Fläche (74) ist und an der unteren der gegenüberliegenden Flächen ein Wulst (70) vorgesehen ist und wobei zwischen der oberen Fläche (74) und einer Oberseite des Wulsts (70) ein Zwischenraum (G) gebildet ist; wobei das Verfahren umfasst, dass:ein kreisförmiger Einsatz (150) aus einem duktilen Metall, der eine um maximal 3 % kleinere Dicke als der Zwischenraum (G) und eine Vielzahl von Öffnungen (152) im Randbereich aufweist, gepresst wird, um einen gepressten Einsatz mit einer gewölbten Kappe (150') und einem abgewinkelten Kragen (154), der die Öffnungen (152) umfasst, zu erzeugen, wobei der Kragen (154) dimensioniert ist, um eng auf den Wulst (70) zu passen;der gepresste Einsatz (150) mit einer Solidustemperatur in dem Formhohlraum auf dem Wulst (70) positioniert wird, wobei sich der gepresste Einsatz (150) bedingt durch seine Dicke und Wölbung beim Schließen der Formwerkzeuge (66, 68) elastisch verformt, sodass Toleranzen ausgeglichen werden und dadurch sowohl ein Kontakt des Einsatzes (150) mit der Fläche (74) des oberen Formwerkzeugs (66) als auch ein vollständiges Schließen der Formwerkzeuge (66, 68) ermöglicht wird; undder Formhohlraum mit einer fließfähigen Gusslegierung oder einem formbaren Polymermaterial bei einer Temperatur gefüllt wird, die niedriger ist als die Solidustemperatur des Einsatzes (150), wobei die fließfähige Gusslegierung oder das formbare Polymermaterial in die Öffnungen (152) eindringt, um den Einsatz (150) an dem Gussteil oder ...

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Номер записи: 80
19-06-2018 дата публикации

Resistance spot welding steel and aluminum workpieces with electrode insert

Номер: US9999939B2
Автор: Blair E. Carlson, David R. Sigler, Pei-Chung Wang
Принадлежит: GM GLOBAL TECHNOLOGY OPERATIONS LLC

A method of resistance spot welding a steel workpiece and an aluminum or aluminum alloy workpiece together includes several steps. In one step a workpiece stack-up is provided. The workpiece stack-up includes a steel workpiece and an aluminum or aluminum alloy workpiece. Another step involves providing a first welding electrode that confronts the aluminum workpiece, and providing a second welding electrode that confronts the steel workpiece. The first welding electrode has an electrode body and an insert that functions to limit or eliminate heat flux into the electrode body. Other steps of the method involve bringing the first and second welding electrodes into contact with opposite sides of the workpiece stack-up and resistance spot welding the stack-up.

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Номер записи: 81
08-11-2011 дата публикации

Method of calibrating a friction stir spot welding system

Номер: US8052029B1
Автор: Blair E. Carlson, David R. Sigler, Mark T. Hall, Robert T. Szymanski
Принадлежит: GM GLOBAL TECHNOLOGY OPERATIONS LLC

A method of performing a plurality of friction stir spot welds with a friction stir spot welding (FSSW) system includes measuring a length of a pin of a weld tool of the FSSW system. The length is compared to a first limit to determine if the length is above or below the first limit. Debris is removed off of a tip of the pin when the length is determined to be above the first limit. The length is also compared to a second limit to determine if the length is above or below the second limit. At least one friction stir spot weld is performed on a workpiece when the length is determined to be less than the first limit and above the second limit.

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Номер записи: 82
09-04-2015 дата публикации

RESISTANCE SPOT WELDING OF STEEL AND ALUMINUM WORKPIECES USING AN INSERTION COVER

Номер: DE102014114334A1
Автор: Anil K. Sachdev, Blair E. Carlson, David R. Sigler, David Yang, Robert T. Szymanski
Принадлежит: GM GLOBAL TECHNOLOGY OPERATIONS LLC

Ein Verfahren zum Widerstandspunktverschweißen eines Stahlwerkstückes und eines Aluminium- oder Aluminiumlegierungs-Werkstückes umfasst mehrere Schritte. Ein Schritt umfasst das Einsetzen einer Abdeckung zwischen dem Aluminium- oder Aluminiumlegierungs-Werkstück und einer benachbarten Schweißelektrode. In einem anderen Schritt wird an einer Schweißstelle die benachbarte Schweißelektrode gegen eine Abdeckung gepresst und eine andere, gegenüberliegende Schweißelektrode wird gegen das Stahlwerkstück gepresst. In einem noch anderen Schritt wird ein elektrischer Strom zwischen den Schweißelektroden geleitet, durch Abdeckung hindurch geleitet und durch die Werkstücke hindurch geleitet, um ein Schweißschmelzbad innerhalb des Aluminium- oder Aluminiumlegierungs-Werkstückes zu initiieren und zum Wachsen zu bringen. A method of spot welding a steel workpiece and an aluminum or aluminum alloy workpiece involves several steps. One step involves inserting a cover between the aluminum or aluminum alloy workpiece and an adjacent welding electrode. In another step, the adjacent welding electrode is pressed against a cover at one weld and another, opposite welding electrode is pressed against the steel workpiece. In yet another step, an electrical current is passed between the welding electrodes, passed through cover, and passed through the workpieces to initiate and grow a weld pool within the aluminum or aluminum alloy workpiece.

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Номер записи: 83
24-01-2019 дата публикации

WHEEL DRIVE BLIND NETWORK CONNECTION SYSTEM AND PROCEDURE

Номер: DE102018117434A1
Автор: Blair E. Carlson, Yongbing Li, Yunwu Ma, Zhongqin Lin
Принадлежит: GM GLOBAL TECHNOLOGY OPERATIONS LLC, Shanghai Jiaotong University

Rührreib-Blindniet-Systeme und -Verfahren werden zum Verbinden von Werkstücken bereitgestellt. Ein FSBR-Verbindungssystem umfasst einen Dorn mit einem Kopf, der eine Spitze bildet. Ein Schaft erstreckt sich vom Kopf und hat einen verengten Abschnitt, der eine Kerbe bildet. Ein hinterer Abschnitt des Dorns ist so konfiguriert, dass er an der Kerbe, die ein gebrochenes Ende bildet, abbricht. Ein Schaft hat auch einen Kopf und einen Körper mit einer durch den Schaft definierten Durchgangsbohrung. Der Schaftkopf weist eine Schulter auf, die eine Fläche bildet, die das erste Werkstück berührt. Der Kopf hat einen äußersten Punkt gegenüber der Fläche. Ein Bereich ist zwischen dem äußersten Punkt des Kopfes und der Fläche definiert. Eine Wand steht von einem anderen Werkstück vor und wird um den Körper herum gebildet. Die Wand hat eine Größe, die durch den Dorn gebildet wird und die so gesteuert wird, dass der Körper sich verformen kann. Friction riveting systems and methods are provided for joining workpieces. An FSBR connection system comprises a mandrel with a head forming a point. A shaft extends from the head and has a narrowed portion forming a notch. A rear portion of the mandrel is configured to break off at the notch forming a broken end. A shaft also has a head and a body with a through bore defined by the shaft. The shaft head has a shoulder that forms a surface that contacts the first workpiece. The head has an outermost point opposite the surface. An area is defined between the outermost point of the head and the area. A wall protrudes from another workpiece and is formed around the body. The wall has a size which is formed by the mandrel and which is controlled so that the body can deform.

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Номер записи: 84
08-09-2020 дата публикации

Mating electrodes for resistance spot welding of aluminum workpieces to steel workpieces

Номер: US10766095B2
Автор: Blair E. Carlson, David R. Sigler, Hui-Ping Wang, Michael J. Karagoulis
Принадлежит: GM GLOBAL TECHNOLOGY OPERATIONS LLC

A spot weld may be formed between an aluminum workpiece and an adjacent overlapping steel workpiece with the use of opposed spot welding electrodes that have mating weld faces designed for engagement with the outer surfaces of the workpiece stack-up assembly. The electrode that engages the stack-up assembly proximate the aluminum workpiece includes a central ascending convex surface and the electrode that engages the stack-up assembly proximate the steel workpiece has an annular surface. The mating weld faces of the first and second spot welding electrodes distribute the passing electrical current along a radially outwardly expanding flow path to provide a more uniform temperature distribution over the intended spot weld interface and may also produce a deformed bonding interface within the formed weld joint. Each of these events can beneficially affect the strength of the weld joint.

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Номер записи: 85
16-02-2017 дата публикации

SYSTEMS AND METHOD FOR REINFORCED ADHESIVE

Номер: DE112014006572T5
Автор: Blair E. Carlson, Jeff Wang, XIN YANG, Yongqiang Li
Принадлежит: GM GLOBAL TECHNOLOGY OPERATIONS LLC

Die vorliegende Offenbarung betrifft ein Verbindungssystem (100), das einen Klebstoff (200) in Kontakt mit einer ersten Kontaktfläche (115) und einer zweiten Kontaktfläche (125) und ein Lotnetz (310) umfasst, das in dem Klebstoff (200) in Kontakt mit der ersten Kontaktfläche (115) angeordnet ist. Die vorliegende Offenbarung betrifft auch ein Verbindungsverfahren zum Herstellen einer lotverstärkten Klebung, die ein erstes Substrat (110) und ein zweites Substrat (120) fügt, umfassend Auftragen eines Klebstoffes (200) auf eine erste Kontaktfläche (115) des ersten Substrats (110), Anordnen eines Lotnetzes (310) zumindest teilweise in dem Klebstoff (200), so dass das Lotnetz (310) mit der ersten Kontaktfläche (115) in Kontakt steht, Verbinden einer zweiten Kontaktfläche (125) des zweiten Substrats (120) mit einem Abschnitt des Klebstoffes (200) gegenüber der ersten Kontaktfläche (115), und Anwenden von Wärme auf die erste Kontaktfläche (115), so dass zumindest ein Abschnitt des Lotnetzes (310) eine Lotverbindungstemperatur erreicht. The present disclosure relates to a bonding system (100) comprising an adhesive (200) in contact with a first contact surface (115) and a second contact surface (125) and a solder mesh (310) in contact with the adhesive (200) the first contact surface (115) is arranged. The present disclosure also relates to a bonding method for producing a solder-reinforced bond that includes a first substrate (110) and a second substrate (120), comprising applying an adhesive (200) to a first contact surface (115) of the first substrate (110). Placing a solder net (310) at least partially in the adhesive (200) so that the solder net (310) is in contact with the first contact surface (115), connecting a second contact surface (125) of the second substrate (120) to a portion of the first substrate Adhesive (200) opposite the first contact surface (115), and applying heat to the first contact surface (115) such that at least a portion of the solder mesh (310) ...

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Номер записи: 86
09-06-2020 дата публикации

Joining of light metal alloy workpieces to steel workpieces using resistance spot welding and adhesive

Номер: US10675702B2
Автор: Blair E. Carlson, David R. Sigler
Принадлежит: GM GLOBAL TECHNOLOGY OPERATIONS LLC

A method of adhesive weld bonding a light metal workpiece and a steel workpiece is disclosed that includes applying a plurality of discrete adhesive ribbons to a faying surface of the light metal workpiece, the faying surface of the steel workpiece, or both faying surfaces, and then assembling the workpieces together to establish one or more adhesive zones between the faying surfaces of the light metal and steel workpieces and a plurality of adhesive free zones amongst the adhesive zone(s). The method further includes forming a resistance spot weld that bonds the the light metal workpiece and the steel workpiece together at a spot weld location within one of the adhesive free zones. The formed spot weld includes a weld joint contained within the light metal workpiece that bonds to the faying interface of the steel workpiece.

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Номер записи: 87
10-12-2015 дата публикации

Cover plate with penetration feature to improve spot welding of AL to steel

Номер: DE102015108796A1
Автор: Blair E. Carlson, David R. Sigler, David Yang, Hui-Ping Wang
Принадлежит: GM GLOBAL TECHNOLOGY OPERATIONS LLC

Ein Verfahren zum Punktschweißen eines Werkstückstapels, der ein Stahlwerkstück und ein benachbartes Aluminiumlegierungs-Werkstück umfasst, beinhaltet, dass ein elektrischer Strom durch die Werkstücke und zwischen entgegengesetzte Schweißelektroden geleitet wird. Die Ausbildung einer Schweißverbindung zwischen den benachbarten Stahl- und Aluminiumlegierungs-Werkstücken wird durch eine Abdeckplatte unterstützt, die zwischen dem Aluminiumlegierungs-Werkstück, das benachbart zu dem Stahlwerkstück liegt, und der auf der gleichen Seite des Werkstückstapels angeordneten Schweißelektrode angeordnet ist. Die Abdeckplatte, die ein Eindringmerkmal umfasst, führt ein Flussmuster und eine Dichte des elektrischen Stromes, der durch die benachbarten Stahl- und Aluminiumlegierungs-Werkstücke fließt, in einer Weise herbei, die dabei hilft, die Festigkeit der Schweißverbindung zu verbessern.

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Номер записи: 88
04-10-2018 дата публикации

Additive manufacturing with laser energy recovery

Номер: DE102018106567A1
Автор: Blair E. Carlson, HyungMin Chae, Jason J. Nolte, John Patrick Spicer, Thomas A. Perry
Принадлежит: GM GLOBAL TECHNOLOGY OPERATIONS LLC

Additive Fertigungssysteme, Bereichsabtastlasersysteme und Verfahren zum Durchführen eines additiven Fertigungsprozesses werden bereitgestellt. Ein exemplarisches additives Fertigungssystem beinhaltet eine Lasererzeugungsvorrichtung zum Erzeugen eines Laserstrahls. Ferner beinhaltet das additive Fertigungssystem ein optisches Element zur Formung eines ersten Teils des Laserstrahls mit einer ersten Polarisation und eines zweiten Teils des Laserstrahls mit einer zweiten Polarisation, die sich von der ersten Polarisation unterscheidet, um ein Bild in dem Laserstrahl zu kodieren. Das additive Fertigungssystem beinhaltet auch einen selektiven Strahlteiler, der so konfiguriert ist, dass dieser den ersten Teil des Laserstrahls auf ein zu sinterndes oder zu schmelzendes Material richtet. Das additive Fertigungssystem beinhaltet ein Rückführungssystem zum Empfangen des zweiten Teils des Laserstrahls.

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Номер записи: 89
12-03-2019 дата публикации

Aperture plate for overheating prevention and wire nozzle protection

Номер: US10226841B2
Автор: Aaron D. Cox, Blair E. Carlson, Hui-Ping Wang, Michael G. Poss, Thomas A. Perry
Принадлежит: GM GLOBAL TECHNOLOGY OPERATIONS LLC

An aperture plate for a welding apparatus includes a body defining an aperture. The body of the aperture plate includes a first end and a second end that is opposite the first end. In addition, the body includes a first surface intersecting the first and second ends. Moreover, the body includes a second surface formed opposite the first surface. The second surface is nonparallel to the first surface.

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Номер записи: 90
14-06-2012 дата публикации

Bimetallic forging part and method

Номер: DE102011115333A1
Автор: Blair E. Carlson, Paul E. Krajewski
Принадлежит: GM GLOBAL TECHNOLOGY OPERATIONS LLC

Ein Verfahren zum Bilden eines Bimetallschmiedeteiles umfasst, dass ein Rohling vorgesehen wird, der zumindest ein erstes Element und ein zweites Element aus einem ersten Metall und einen Einsatz aus einem zweiten Metall umfasst. Ein Rohling ist derart ausgebildet, dass der Einsatz im Wesentlichen von einer Schale umschlossen sein kann, die durch das erste Element und das zweite Element definiert ist. Der Rohling wird geschmiedet, um ein Bimetallschmiedeteil zu bilden, das einen äußeren Abschnitt, der durch die Schale definiert ist, einen inneren Abschnitt, der durch den Einsatz definiert ist, und eine Grenzflächenschicht dazwischen umfasst. In einem nicht einschränkenden Beispiel besteht das erste Metall im Wesentlichen aus Aluminium und das zweite Metall besteht im Wesentlichen aus Magnesium. In einem nicht einschränkenden Beispiel kann der Rohling geschmiedet werden, um ein Fahrzeugrad zu bilden, das eine Aluminiumhaut umfasst, die einen inneren Magnesiumabschnitt im Wesentlichen umschließt, um dem Rad ein hohes Festigkeit/Gewicht-Verhältnis und ein verbessertes Korrosionsverhalten zu verleihen. A method for forming a bimetallic forging comprises providing a blank that includes at least a first element and a second element made of a first metal and an insert made of a second metal. A blank is designed such that the insert can be essentially enclosed by a shell, which is defined by the first element and the second element. The blank is forged to form a bimetallic forging that includes an outer portion defined by the shell, an inner portion defined by the insert, and an interface layer therebetween. In a non-limiting example, the first metal is essentially aluminum and the second metal is essentially magnesium. In one non-limiting example, the blank can be forged to form a vehicle wheel that includes an aluminum skin that substantially encloses an inner magnesium portion to provide the wheel with a high strength / weight ratio and improved corrosion behavior.

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Номер записи: 91
09-02-2017 дата публикации

APERTURATE PLATE AS OVERHEAT AND LINE NOZZLE PROTECTION

Номер: DE102016214290A1
Автор: Aaron D. Cox, Blair E. Carlson, Hui-Ping Wang, Michael G. Poss, Thomas A. Perry
Принадлежит: GM GLOBAL TECHNOLOGY OPERATIONS LLC

Eine Aperturplatte für ein Schweißgerät mit einem Körper, der eine Öffnung hat. Der Körper der Aperturplatte besteht aus zwei sich gegenüberliegenden Enden (erstes und zweites Ende). Zusätzlich hat der Körper eine erste Oberfläche die vom ersten bis zum zweiten Ende reicht. Außerdem gibt es eine zweite, der ersten Fläche gegenüberliegende Oberfläche. Die zweite Oberfläche ist nicht parallel zur ersten Oberfläche. An aperture plate for a welder with a body having an opening. The body of the aperture plate consists of two opposite ends (first and second ends). In addition, the body has a first surface which extends from the first to the second end. There is also a second surface opposite the first surface. The second surface is not parallel to the first surface.

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Номер записи: 92
05-07-2016 дата публикации

Method for joining workpieces

Номер: US9381563B2
Автор: Blair E. Carlson, Jorge F. Arinez, Saul S. Lee, Yongqiang Li
Принадлежит: GM GLOBAL TECHNOLOGY OPERATIONS LLC

A method can be used for joining workpieces using a fastener. The fastener includes a first head and a shank extending from the first head along a fastener axis. The joining method includes the following steps: (a) rotating a fastener about a fastener axis; (b) moving the fastener toward the first and second workpieces while the fastener rotates about the fastener axis such that the fastener increases the temperature in the first and second workpieces in order to soften and pierce the first and second workpieces along the fastener axis; and (c) advancing the fastener through the first and second workpieces and toward an open cavity of a die after piercing the first and second workpieces while the fastener rotates about the fastener axis such that the shank is partially disposed inside the open cavity in order to form a second head.

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Номер записи: 93
23-08-2012 дата публикации

Method of joining by roll flanging and solid-state welding and system for the same

Номер: DE102012002254A1
Автор: Blair E. Carlson, David R. Sigler, James G. Schroth, John E. Carsley
Принадлежит: GM GLOBAL TECHNOLOGY OPERATIONS LLC

Ein Verfahren zum Fügen eines ersten Werkstückes und eines zweiten Werkstückes, z. B. Autoschließbleche, umfasst, dass die Werkstücke auf einer Spannvorrichtung getragen werden und die Werkstücke dann durch eine erste Festkörperschweißung mit einem schwingenden Rollenkopf einer Werkzeuganordnung wie z. B. einer robotergesteuerten Ultraschallnahtschweißmaschine aneinander gefügt werden. Als Nächstes wird ein Schenkel des zweiten Werkstückes unter Verwendung desselben oder eines anderen Rollenkopfes um einen äußeren Umfang des ersten Werkstückes herum gebördelt, wobei die Werkstücke durch die Spannvorrichtung getragen werden. Dann wird der gebördelte Schenkel durch eine zweite Festkörperschweißung mit dem schwingenden Rollenkopf der robotergesteuerten Ultraschallnahtschweißmaschine an das erste Werkstück gefügt. Es ist auch ein System zum Fügen eines ersten und eines zweiten Werkstückes vorgesehen. A method for joining a first workpiece and a second workpiece, for. B. Auto striking plates, that the workpieces are supported on a jig and then the workpieces by a first solid-state welding with a vibrating roller head of a tool assembly such. B. a robot-controlled Ultraschallnahtschweißmaschine be joined together. Next, a leg of the second workpiece is crimped around an outer periphery of the first workpiece using the same or another roller head, the workpieces being carried by the tensioner. Then the crimped leg is joined to the first workpiece by a second solid-state welding with the oscillating roller head of the robot-controlled ultrasonic seam welding machine. There is also provided a system for joining a first and a second workpiece.

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Номер записи: 94
16-06-2020 дата публикации

Resistance spot welding of aluminum-to-aluminum, aluminum-to-steel, and steel-to-steel in a specified sequence and using a cover

Номер: US10682724B2
Автор: Blair E. Carlson, David R. Sigler, Michael J. Karagoulis
Принадлежит: GM GLOBAL TECHNOLOGY OPERATIONS LLC

A series of many electrical resistance spot welds is to be formed in members of an assembled, but un-joined, body that presents workpiece stack-ups of various combinations of metal workpieces including all aluminum workpieces, all steel workpieces, and a combination of aluminum and steel workpieces. A pair of spot welding electrodes, each with a specified weld face that includes oxide-disrupting features, is used to form the required numbers of aluminum-to-aluminum spot welds, aluminum-to-steel spot welds, and steel-to-steel spot welds. A predetermined sequence of forming the various spot welds may be specified for extending the number of spot welds that can be made before the weld faces must be restored. And, during at least one of the aluminum-to-steel spot welds, a cover is inserted between the weld face of one of the welding electrodes and a side of a workpiece stack-up that includes the adjacent aluminum and steel workpieces.

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Номер записи: 95
16-04-2019 дата публикации

Resistive welding electrode and method for spot welding steel and aluminum alloy workpieces with the resistive welding electrode

Номер: US10259071B2
Автор: Blair E. Carlson, David P. Kelly, David R. Sigler, Michael J. Karagoulis
Принадлежит: GM GLOBAL TECHNOLOGY OPERATIONS LLC

A resistive welding electrode includes at least a weld face constructed of a refractory-based material that exhibits an electrical conductivity that is less than or equal to 65% of the electrical conductivity of commercially pure annealed copper as defined by the International Annealed Copper Standard (IACS). A method of using the resistive welding electrode to resistance spot weld a workpiece stack-up that includes an aluminum alloy workpiece and steel workpiece that overlap and contact each other at a faying interface is also disclosed.

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Номер записи: 96
09-06-2016 дата публикации

A method of forming a bimetal forging and blank for forming by forging

Номер: DE102011115333B4
Автор: Blair E. Carlson, Paul E. Krajewski
Принадлежит: GM GLOBAL TECHNOLOGY OPERATIONS LLC

Verfahren zum Bilden eines Bimetall-Schmiedeteiles (30), wobei das Verfahren umfasst, dass: ein erstes Element (12) vorgesehen wird, das aus einem ersten Metall hergestellt ist, wobei das erste Metall Aluminium oder eine Aluminiumlegierung ist; ein zweites Element (16) vorgesehen wird, das aus dem ersten Metall hergestellt ist; ein Einsatz (14) vorgesehen wird, der aus einem zweiten Metall hergestellt ist, wobei das zweite Metall Magnesium oder eine Magnesiumlegierung ist; ein Rohling (10) gebildet wird, der aus dem ersten Element (12), dem zweiten Element (16) und dem Einsatz (14) besteht; wobei der Rohling (10) derart ausgebildet wird, dass der Einsatz (14) von einer Schale (20) umschlossen ist, die durch das erste Element (12) und das zweite Element (16) definiert ist; und der Rohling (10) geschmiedet wird, um das Schmiedeteil (30) zu bilden; dadurch gekennzeichnet, dass das erste Element (12) und das zweite Element (16) durch eine schmiedbare Naht (18) mittels Reibrührschweißen verbunden werden. A method of forming a bimetallic forgings (30), the method comprising: providing a first member (12) made of a first metal, the first metal being aluminum or an aluminum alloy; a second member (16) made of the first metal is provided; providing an insert (14) made of a second metal, the second metal being magnesium or a magnesium alloy; forming a blank (10) consisting of the first member (12), the second member (16) and the insert (14); wherein the blank (10) is formed such that the insert (14) is enclosed by a shell (20) defined by the first element (12) and the second element (16); and the blank (10) is forged to form the forging (30); characterized in that the first member (12) and the second member (16) are connected by a malleable seam (18) by friction stir welding.

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Номер записи: 97
25-05-2023 дата публикации

AIR MANAGEMENT SYSTEM FOR LASER WELDING WITH AIR FLOW OPTIMIZING DEFLECTOR

Номер: DE102022123817A1
Автор: Ahmed Alkhafaji, Baixuan Yang, Blair E. Carlson, Joshua Lee Solomon, Kuo-Huey CHEN
Принадлежит: GM GLOBAL TECHNOLOGY OPERATIONS LLC

Es werden Luftmanagementsysteme zur Optimierung des Luftstroms beim Laserschweißen mit Deflektoren angeboten. Ein System für ein Schweißgerät umfasst ein Gebläse zur Erzeugung eines Luftstroms. Ein Verteilerschacht nimmt den Luftstrom auf, lenkt ihn auf das Werkstück und definiert einen Auslass, der dem Werkstück zugewandt ist, um den Luftstrom auf das Werkstück zu lenken. Ein Deflektor neben dem Auslass ist als konischer Abschnitt ausgebildet, der vom Verteilerschacht zum Werkstück hin konvergiert und durch eine abgewinkelte Wand mit einer offenen Mitte definiert ist. Der Deflektor konzentriert den Luftstrom, um dem Luftstrom nach dem Verlassen des Auslasses einen Geschwindigkeitsanstieg zu verleihen und dem Luftstrom eine günstige Richtungskomponente in Richtung einer Schweißzone zu verleihen sowie die Laserlinse zu schützen, indem die nach unten gerichtete Impulskraft des Luftstroms erhöht wird, um ein mögliches Auftreffen von Spritzern auf die Linse zu verhindern. Air management systems are offered to optimize airflow during laser welding with deflectors. A system for a welding device includes a fan for generating an air flow. A plenum receives the airflow, directs it onto the workpiece and defines an outlet facing the workpiece to direct the airflow onto the workpiece. A deflector adjacent the outlet is formed as a conical section converging from the plenum toward the workpiece and defined by an angled wall with an open center. The deflector concentrates the airflow to give the airflow an increase in velocity after exiting the outlet and to give the airflow a favorable directional component towards a welding zone as well as to protect the laser lens by increasing the downward impulse force of the airflow to avoid a possible prevent splashes from hitting the lens.

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Номер записи: 98
06-07-2023 дата публикации

Method for spot welding a stack of workpieces using a cover plate

Номер: DE102015108796B4
Автор: Blair E. Carlson, David R. Sigler, David Yang, Hui-Ping Wang
Принадлежит: GM GLOBAL TECHNOLOGY OPERATIONS LLC

Verfahren zum Punktschweißen eines Werkstückstapels (14), der ein Stahlwerkstück (20) und ein benachbartes Aluminiumlegierungs-Werkstück (22) umfasst, wobei das Verfahren umfasst, dass:ein Werkstückstapel (14) vorgesehen wird, welcher ein Stahlwerkstück (20) und ein Aluminiumlegierungs-Werkstück (22) umfasst, welches das Stahlwerkstück (20) überlappt und zu diesem benachbart liegt, um eine Stoßgrenzfläche (32) an einer Schweißstelle (16) herzustellen, wobei der Werkstückstapel (14) eine erste Seite (34) und eine zweite Seite (36) aufweist,wobei die erste Seite (34) des Werkstückstapel (14) nahe dem Stahlwerkstück (20) liegt und die zweite Seite (36) des Werkstückstapels (14) nahe dem Aluminiumlegierungs-Werkstück (22) liegt;eine Abdeckplatte (10) benachbart zu der zweiten Seite (36) des Werkstückstapels (14) angeordnet wird, wobei die Abdeckplatte (10) eine innere Oberfläche (38), die der zweiten Seite (36) des Werkstückstapels (14) gegenübersteht, und eine äußere Oberfläche (40) aufweist, die in die entgegengesetzte Richtung von der inneren Oberfläche (38) weist, wobei die Abdeckplatte (10) ferner ein Eindringmerkmal (12) umfasst, das mit der Schweißstelle (16) ausgerichtet ist, wobei das Eindringmerkmal (12) entweder eine Durchgangsbohrung (62), welche sich vollständig durch die Abdeckplatte (10) von der inneren Oberfläche (38) der Abdeckplatte (10) zu der äußeren Oberfläche (40) der Abdeckplatte (10) hindurch erstreckt, odereine Vertiefung (64, 66) ist, welche die Dicke der Abdeckplatte (10) teilweise durchquert;eine erste Schweißfläche (54) einer ersten Schweißelektrode (48) gegen die erste Seite (34) des Werkstückstapels (14) gepresst wird und eine zweite Schweißfläche (56) einer zweiten Schweißelektrode (52) gegen die äußere Oberfläche (40) der Abdeckplatte (10) über dem Eindringmerkmal (12) gepresst wird, wobei die erste und die zweite Schweißfläche (54, 56) der ersten und der zweiten Schweißelektrode (48, 52) an der Schweißstelle (16) flächig ausgerichtet ...

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Номер записи: 99
14-03-2013 дата публикации

Wasserlose Wärmerohr-Widerstandsschweisselektrode

Номер: DE102012215303A1
Автор: Blair E. Carlson, Pei-Chung Wang
Принадлежит: GM GLOBAL TECHNOLOGY OPERATIONS LLC

Eine Vorrichtung zum Widerstandsschweißen mit einer Schweißmaschine umfasst ein Wärmerohr mit einem hohlen Rohr und eine Schweißelektrode, die um einen Abschnitt des Wärmerohres herum befestigt ist. Die Schweißelektrode und das Wärmerohr sind konduktiv gekoppelt, um Wärme über eine Innenfläche der Schweißelektrode hinweg zu leiten.

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Номер записи: 100