A method of manufacturing a secondary battery including a negative electrode collector connected to a layered negative electrode core body exposed portion by welding, the method including a first step of disposing a core body connection of the negative electrode collector on an outer surface side of a layered negative electrode core body exposed portion so that a recess in the core body connection opposes the layered negative electrode core body exposed portion, a second step of pressing, with a pressing member, a portion in the core body connection where the recess is formed, forming a deformed portion, and contacting the deformed portion to the layered negative electrode core body exposed portion, and a third step of abutting an electrode for resistance welding against the negative electrode collector and resistance welding the negative electrode collector and the layered negative electrode core body exposed portion to each other.

Sandwich panels may include an intermediate thermoplastic layer disposed between two metallic cover layers. Some methods for welding a sandwich panel to a metallic component may involve heating a region of the sandwich panel with a preheating current so that the thermoplastic layer is softened and by compression of the cover layers is displaced from the welding region. A tack-welding current flowing between first and second welding electrodes may weld the cover layers together, and a welding current may be used to weld the metallic cover layers to the metallic component. In some cases, the first welding electrode may be in contact with one of the metallic cover layers, and the second welding electrode may be in contact with the metallic component. As a result, the sandwich panel may be joined to the metallic component in a short cycle time without blisters and faults arising in the sandwich component.

Sandwich panels may include an intermediate thermoplastic layer disposed between two metallic cover layers. Some methods for welding a sandwich panel to a metallic component may involve heating a region of the sandwich panel with a preheating current so that the thermoplastic layer is softened and by compression of the cover layers is displaced from the welding region. A tack-welding current flowing between first and second welding electrodes may weld the cover layers together, and a welding current may be used to weld the metallic cover layers to the metallic component. In some cases, the first welding electrode may be in contact with one of the metallic cover layers, and the second welding electrode may be in contact with the metallic component. As a result, the sandwich panel may be joined to the metallic component in a short cycle time without blisters and faults arising in the sandwich component.

A method of producing a chassis module (1) with a structural component (3) having a through-going aperture (5) into which a ball joint housing (7) is inserted. An outer periphery of the ball joint housing (7) is connected all round to an edge section (9) of the aperture (5) by a first material-cohesive joining (11) without a filler. In order to stabilize the ball joint housing (7) in the aperture (5), the ball joint housing (7) is additionally connected all round to an inner wall section (13) of the aperture (5) at a location spaced away from the edge section (9), by a second material-cohesive joining (15) without a filler. The chassis module (1) is produced by the method, and the chassis module is in the form of a flanged connector (1) or a multi-point link.

A method of producing a chassis module (1) with a structural component (3) having a through-going aperture (5) into which a ball joint housing (7) is inserted. An outer periphery of the ball joint housing (7) is connected all round to an edge section (9) of the aperture (5) by a first material-cohesive joining (11) without a filler. In order to stabilize the ball joint housing (7) in the aperture (5), the ball joint housing (7) is additionally connected all round to an inner wall section (13) of the aperture (5) at a location spaced away from the edge section (9), by a second material-cohesive joining (15) without a filler. The chassis module (1) is produced by the method, and the chassis module is in the form of a flanged connector (1) or a multi-point link.

A method of manufacturing a resistance weld in at least three overlying sheet metal layers includes the steps of: (1) providing a first sheet metal layer having a first thickness; (2) providing a second sheet metal layer having a second thickness; (3) providing a filler material on the second sheet metal layer; (4) providing a third sheet metal layer having a third thickness onto the filler material and the second sheet metal layer wherein the third thickness is less than each of the first and the second thicknesses; (5) pressing a pair of welding electrodes against a pair of opposing outer surfaces with the filler material disposed therebetween; and (6) passing an electric current between the pair of electrodes through the filler material and the first, second, and third sheet metal layers to form a weld nugget which penetrates into at least the first and second sheet metal layers.

A welding assistance member with electrically-conductive properties is used for spot-welding performed by sandwiching a second member between electrically-conductive first members different in material from the second member. The welding assistance member is fitted into a hole extending through the second member so as to allow for spot-welding of the first members to each other from opposite sides in the hole. The welding assistance member includes: a main body that has a size and shape that allow a gap to be formed between the main body and an inner side surface of the hole when the main body is fitted in the hole; and a position maintaining component that is provided at an outer side of the main body, has heat, heat resisting, and electrically insulating properties, and maintains the main body in a separated state from the inner side surface. A spot-welding method uses this welding assistance member.

A method for manufacturing a joined article, the method including providing a first metal member E (ST1), providing a second metal member D, the second metal member D reaching a melting point before the first metal member E when the second metal member D is brought into contact with the first metal member E and an electric current is applied between the two metal members (ST2), preheating the first metal member E using a high-frequency induced electric current (ST3), applying pressure on the first metal member E and the second metal member D (ST4), applying an electric current between the first metal member E and the second metal member D at a timing at which a temperature of the first metal member E has reached a prescribed temperature TS4 due to the preheating (ST5), and joining the first and second metal members E and D through the application of pressure and the application of an electric current (ST4, ST5). Through the adoption of such a method, the present invention provides: a method for manufacturing a joined article in which joint length is adequate even when metals are joined together that are such that, for example, one reaches a melting point before the other during electric current joining; and a joining apparatus for joining such metal members together.

A method for manufacturing a joined article, the method including providing a first metal member E (ST1), providing a second metal member D, the second metal member D reaching a melting point before the first metal member E when the second metal member D is brought into contact with the first metal member E and an electric current is applied between the two metal members (ST2), preheating the first metal member E using a high-frequency induced electric current (ST3), applying pressure on the first metal member E and the second metal member D (ST4), applying an electric current between the first metal member E and the second metal member D at a timing at which a temperature of the first metal member E has reached a prescribed temperature TS4 due to the preheating (ST5), and joining the first and second metal members E and D through the application of pressure and the application of an electric current (ST4, ST5). Through the adoption of such a method, the present invention provides: a method for manufacturing a joined article in which joint length is adequate even when metals are joined together that are such that, for example, one reaches a melting point before the other during electric current joining; and a joining apparatus for joining such metal members together.

A method to mitigate liquid metal embrittlement cracking in resistance welding of galvanized steels includes modifying at least one face of a steel member to create a first workpiece by: applying a zinc containing material in a first layer to the at least one face of the steel member; and spraying a second layer of a copper containing material onto the first layer of the zinc containing material. The at least one face of the first workpiece is abutted to a second workpiece of a steel material. A resistance welding operation is performed to join the first workpiece to the second workpiece. A temperature of the resistance welding operation locally melts the zinc containing material and the copper containing material to create a brass alloy of the zinc containing material and the copper containing material.