A dual pass seam welding method for steels having a Ceq of greater than about 0.45. The first pass welds the immediately anneals the weld. On the second pass, the welder is disengaged, and the weld is subjected to a second anneal.

A workpiece of Ti or a Ti alloy includes a surface with a coating layer of titanium nitride. A region of the surface includes a connection zone of a Ti—N solid solution alloy. A second Ti or Ti alloy workpiece is contacted with the connection zone, and a weld joint is formed across the connection zone with a resistance welding process. The weld joint extends into the first Ti workpiece and the second Ti workpiece.

A resistance spot welding method of galvanized high-strength steel with good joint performance, in which three welding pulses are used within one spot welding schedule. The method includes applying a first welding pulse and a second welding pulse which are used for generating a nugget and suppressing the generation of liquid metal embrittlement (LME) cracks, respectively. The first welding pulse generates a nugget having a diameter of 3.75T.sup.1/2-4.25T.sup.1/2 in which T represents a plate thickness. The second welding pulse causes the nugget to grow at a rate less than a rate of growth during the first welding pulse. A third welding pulse, which is a tempering pulse, is applied for improving plasticity of a welding spot.

Disclosed is a method for manufacturing a welded member in which a workpiece made of a high tensile material and a welding object are welded. The method includes welding the workpiece and the welding object such that welded portions are formed between the workpiece and the welding object by performing projection welding. The method also includes applying a cancellation stress to the welded member after the projection welding, so that a stress that is generated in the welded portions after the projection welding and acts in a direction to pull the welded portions close to each other is canceled.

Disclosed is a method for manufacturing a welded member in which a workpiece made of a high tensile material and a welding object are welded. The method includes welding the workpiece and the welding object such that welded portions are formed between the workpiece and the welding object by performing projection welding. The method also includes applying a cancellation stress to the welded member after the projection welding, so that a stress that is generated in the welded portions after the projection welding and acts in a direction to pull the welded portions close to each other is canceled.

A steel workpiece includes an alloy substrate comprising iron, about 1.4 to about 2.0 weight percent aluminum, and about 0 to about 1.0 weight percent silicon. The steel workpiece further includes a coating comprising zinc. A method of spot welding a workpiece stack-up that includes a pair of the steel workpieces includes providing the stack-up, contacting first and second electrodes to the steel workpieces, passing an electrical current through the stack-up, forming a weld nugget from molten mixing of the alloy substrates of the pair of steel workpieces, forming a boundary layer between the coating and the alloy substrate from dispersion of the coating into the alloy substrate and reaction of the zinc with the aluminum and the silicon to prevent molten mixing of the coating within the alloy substrate, and ceasing passage of the electrical current.

A method for joining of at least two materials, non-weldable directly to each other with thermal joining processes in a lap joint configuration includes a two step sequence including a first step to apply a thermomechanical or mechanical surface protection layer on the surface of a (stainless) steel substrate and a second step where, a thermal joining process is used to weld the sprayed layer with an applied aluminum sheet without having brittle intermetallic phases in the whole material configuration.

A system for increasing joint strength and reducing embrittlement in a resistance spot weld of metal workpieces is disclosed. The system comprises a stackup of first and second metal workpieces, and an interface member disposed between the first and second metal workpieces. The interface member comprises a peripheral wall defining a hollow inner portion. The peripheral wall has a first open end extending to a second open end. The first open end is in contact with the first metal workpiece defining a first weld portion thereon. The second open end is in contact with the second metal workpiece defining a second weld portion thereon. The system further comprises a first electrode configured to contact the first metal workpiece to heat the peripheral wall at the first weld portion and join the first metal workpiece with the first open end of the peripheral wall. The system further comprises a second electrode configured to contact the second metal workpiece to heat the peripheral wall at the second weld portion and join the second metal workpiece with the second open end of the peripheral wall to define a weld joint. The system further comprises a power source configured to power the first and second electrodes and a controller configured to control the power to the first and second electrodes to heat the peripheral wall.

Methods for resistance welding, resistance-welded assemblies, and vehicles including resistance-welded assemblies are provided. The method includes providing a workpiece stack-up including first and second workpieces and an intermediate material located between the faying surfaces thereof. At least one of the first workpiece and the second workpiece is formed of a first metal alloy with a first concentration of an alloying element, and the intermediate material is formed of a second metal alloy of the first metal and a second concentration of the alloying element that is less than the first concentration. The method includes bringing electrodes into contact with the workpieces, passing an electrical current therebetween to form a molten weld pool, and cooling the molten weld pool into a weld nugget that forms all or part of a weld joint between the workpieces and has a composition that is a mixture of the workpieces and the intermediate material.

An airfoil component for attaching to a cropped airfoil is provided. The cropped airfoil comprises a cropped airfoil attachment section and a cropped first side opposite a cropped second side, which each extend axially between a cropped first edge and a cropped second edge to define a cropped chord length. The airfoil component comprises a body having a component first side opposite a component second side. The body defines an attachment section for attaching the airfoil component to the cropped airfoil at the cropped airfoil attachment section. The attachment section extends axially between a component first edge and a component second edge to define a component chord length, and the attachment section is oversized with respect to the cropped airfoil attachment section such that the component chord length is longer than the cropped chord length. Systems and methods also are provided.