A method of assembling a first part made from a metal and a second part includes providing a first part comprising an assembly surface, and a second part comprising at least one through orifice. At least part of the second part is arranged on the assembly surface such that the orifice extends across from the assembly surface. A metal connecting part is positioned on the orifice to cover the orifice across from the assembly surface. The connecting part and/or the assembly surface are projected on one another to obtain high-speed plating and welding between the connecting part and the surface part.

An apparatus for applying a magnetic pressure to a work piece includes an inductor configured to be disposed in proximity to the work piece and a controller electrically connected to the inductor. The controller is configured to control a supply of electrical power in order to output a first voltage over a selected frequency range to determine a first frequency that provides a maximum current to the inductor or a second frequency that provides a current within a selected range of the maximum current to the inductor.

An apparatus for applying a magnetic pressure to a work piece includes an inductor configured to be disposed in proximity to the work piece and a controller electrically connected to the inductor. The controller is configured to control a supply of electrical power in order to output a first voltage over a selected frequency range to determine a first frequency that provides a maximum current to the inductor or a second frequency that provides a current within a selected range of the maximum current to the inductor.

An electromagnetic crimp terminal includes an electric wire and a terminal plate. The electric wire includes a conductor portion, an insulation portion which covers the conductor portion, and an exposed portion which is a part of the conductor portion exposed from the insulation portion. The terminal plate includes a crimped portion. The crimped portion is crimped onto the exposed portion. The crimped portion includes a first side edge and a second side edge. A vicinity of the first side edge and a vicinity of the second side edge overlap each other.

A battery module housing having a rectangular tube structure and method for forming the battery module housing is provided. The battery module housing includes a first side plate and a second side plate, the first and second side plates having target portions at upper and lower ends thereof, respectively, and spacers vertically protruding from the target portions; and a top plate and a bottom plate disposed upper and lower portions of the first and second side plates, respectively, each of the top and bottom plates having flyer portions supported on the spacers of the first and second side plates. The flyer portions of the top and bottom plates are joined to the target portions by means of electromagnetic pulse welding such that outer portions of the flyer portions contact the target portions and inner portions of the flyer portions are separated from the target portions by a gap.

Joining methods and corresponding structures are disclosed. In some instances, a method for joining two or more components may include generating a shockwave in a first component to form a jet of a material of the first component directed towards a second component. The jet may penetrate the second component to connect the first component with the second component. Articles of pre-joined and joined components are also described.

The present disclosure provides a system and method for measuring energy conversion efficiency of an inertia friction welding (IFW) process in a non-contact manner. The system includes an IFW machine, a Hall sensor, a data acquisition module, a processing module and a stabilized direct current (DC) power supply. The stabilized DC power supply provides electrical energy for the Hall sensor. The Hall sensor is provided beside a flywheel of the IFW machine, so that the flywheel is within a detection range of the Hall sensor. A magnet is provided on the flywheel. The data acquisition module acquires a Hall electric potential change caused by a relative movement between the magnet and the Hall sensor during the IFW process, and transmits the Hall electric potential change to the processing module to calculate the energy conversion efficiency of the IFW machine.

The present disclosure provides a system and method for measuring energy conversion efficiency of an inertia friction welding (IFW) process in a non-contact manner. The system includes an IFW machine, a Hall sensor, a data acquisition module, a processing module and a stabilized direct current (DC) power supply. The stabilized DC power supply provides electrical energy for the Hall sensor. The Hall sensor is provided beside a flywheel of the IFW machine, so that the flywheel is within a detection range of the Hall sensor. A magnet is provided on the flywheel. The data acquisition module acquires a Hall electric potential change caused by a relative movement between the magnet and the Hall sensor during the IFW process, and transmits the Hall electric potential change to the processing module to calculate the energy conversion efficiency of the IFW machine.

A method for forming an impact weld used in an additive manufacturing process is provided. The method includes providing a metallic material for impact welding to a substrate. The metallic material is propelled toward the substrate with a sufficient velocity to form an impact weld for welding the metallic material to the substrate. Further, the method includes traversing the substrate in a direction relative to a direction from which the metallic material is propelled and repeating the propelling so that a layer of additive material is deposited on the substrate as desired. In addition, a method for forming an impact welding used in an additive manufacturing process via discharge actuated arrangement is provided.

A method for forming an impact weld used in an additive manufacturing process is provided. The method includes providing a metallic material for impact welding to a substrate. The metallic material is propelled toward the substrate with a sufficient velocity to form an impact weld for welding the metallic material to the substrate. Further, the method includes traversing the substrate in a direction relative to a direction from which the metallic material is propelled and repeating the propelling so that a layer of additive material is deposited on the substrate as desired. In addition, a method for forming an impact welding used in an additive manufacturing process via discharge actuated arrangement is provided.