The present invention consists in a method of welding a nickel strength lug with a bronze connecting pin and a brass contact ring in an accelerometer sensor, the strength lug being interleaved between the connecting pin and the contact ring, the welding being effected electrically with the strength lug pressed simultaneously against the connecting pin and the contact ring. Before welding, the strength lug undergoes deformation of its external surface at least on each of two portions of the surface respectively facing the connecting pin and the contact ring, the surface deformation creating on each of the portions asperities intended to come into local contact with the connecting pin and the contact ring, respectively.

The present invention consists in a method of welding a nickel strength lug with a bronze connecting pin and a brass contact ring in an accelerometer sensor, the strength lug being interleaved between the connecting pin and the contact ring, the welding being effected electrically with the strength lug pressed simultaneously against the connecting pin and the contact ring. Before welding, the strength lug undergoes deformation of its external surface at least on each of two portions of the surface respectively facing the connecting pin and the contact ring, the surface deformation creating on each of the portions asperities intended to come into local contact with the connecting pin and the contact ring, respectively.

A system may include a current source; a first metal or alloy component with a first major surface electrically coupled to the current source; a second metal or alloy component with a second major surface electrically coupled in series to the first component and the current source via an external electrical conductor, where the first and second major surfaces are positioned adjacent to each other to define a joint region; a metal or alloy powder disposed in at least a portion of the joint region; and a controller. The controller may be configured to cause the current source to output an alternating current that conducts through the first component and the second component to induce magnetic eddy currents, magnetic hysteresis, or both within at least a portion of the metal or alloy powder disposed in at least the first portion of the joint region.

A welded assembly includes a first component including an aluminum material, a second component including a stainless steel, and a third component including a steel material. An ultrasonic weld is formed between the first and second components to join them and form a stack. A sealant and/or adhesive may be applied to the stack. A resistance spot weld is used to join the third component to the stack to form the welded assembly. The resistance spot weld encompasses a portion of the first, second, and third components, and a portion of the ultrasonic weld. The resistance spot weld is completely encompassed in the welded assembly, and thus is sealed from electrolyte in a surrounding environment.

A welded assembly includes a first component including an aluminum material, a second component including a stainless steel, and a third component including a steel material. An ultrasonic weld is formed between the first and second components to join them and form a stack. A sealant and/or adhesive may be applied to the stack. A resistance spot weld is used to join the third component to the stack to form the welded assembly. The resistance spot weld encompasses a portion of the first, second, and third components, and a portion of the ultrasonic weld. The resistance spot weld is completely encompassed in the welded assembly, and thus is sealed from electrolyte in a surrounding environment.

A method of resistance spot welding a workpiece stack-up that that includes an aluminum workpiece and an adjacent overlapping steel workpiece involves assembling the workpiece stack-up so that an intermediate metallurgical additive is positioned between the faying surfaces of the aluminum and steel workpieces. The intermediate metallurgical additive includes at least one of carbon, silicon, nickel, manganese, chromium, cobalt, or copper, and has the capability to counteract the growth and formation of Fe—Al intermetallic compounds within a molten metal weld pool created within the aluminum workpiece during resistance spot welding of the workpiece stack-up. In certain aspects of the disclosed method, the intermediate metallurgical additive may be one or more metallurgical additive deposits that are deposited onto the faying surface of the aluminum workpiece or the faying surface of the steel workpiece by an oscillating wire arc welding process.

A method of resistance spot welding a workpiece stack-up that that includes an aluminum workpiece and an adjacent overlapping steel workpiece involves assembling the workpiece stack-up so that an intermediate metallurgical additive is positioned between the faying surfaces of the aluminum and steel workpieces. The intermediate metallurgical additive includes at least one of carbon, silicon, nickel, manganese, chromium, cobalt, or copper, and has the capability to counteract the growth and formation of Fe—Al intermetallic compounds within a molten metal weld pool created within the aluminum workpiece during resistance spot welding of the workpiece stack-up. In certain aspects of the disclosed method, the intermediate metallurgical additive may be one or more metallurgical additive deposits that are deposited onto the faying surface of the aluminum workpiece or the faying surface of the steel workpiece by an oscillating wire arc welding process.

A method for manufacturing a hot-stamped steel sheet is provided. The method includes forming a welding portion of one steel sheet of a plurality of steel sheets to be joined. The welding portion has a thickness that is greater than that of a non-welding portion. The method also includes aligning welding portions of the plurality of steel sheets with each other, and joining the plurality of steel sheets by spot welding between the welding portions.

A method for manufacturing a hot-stamped steel sheet is provided. The method includes forming a welding portion of one steel sheet of a plurality of steel sheets to be joined. The welding portion has a thickness that is greater than that of a non-welding portion. The method also includes aligning welding portions of the plurality of steel sheets with each other, and joining the plurality of steel sheets by spot welding between the welding portions.

A method of resistance spot welding an aluminum workpiece and an adjacent overlapping steel workpiece is disclosed in which a source of a reactive metal in a diffusible state is located along a faying interface of an aluminum workpiece and an adjacent overlapping steel workpiece. The source of the reactive metal in a diffusible state may take on a variety of forms including (1) a composite adhesive layer that includes reactive particles dispersed throughout a structural thermosetting adhesive matrix or (1) a reactive alloy layer that confronts and is in proximate contact with a faying surface of the aluminum workpiece. Once the source of a reactive material in a diffusible state is in place and the workpiece stack-up is assembled, an electrical current is passed through the workpiece stack-up and between a set of opposed welding electrodes at a weld zone to ultimately produce a weld joint.