The invention relates to a device for welding rod-shaped electrical conductors (28, 29) and to a sonotrode (16) for such a device, comprising a compression space for receiving two connection regions (26, 27) of the conductors (28, 29) to be connected, said connection regions (26, 27) extending in a first axial direction (x-axis), the compression space being defined by a working surface (19) of a sonotrode (16), which transmits ultrasonic vibrations, and a counterface of an anvil at two opposite sides in a second axial direction (z-axis) and by a boundary surface of a slider element, which is displaceable in the second axial direction (z-axis), and a boundary surface of a boundary element on two opposite sides in a third axial direction (y-axis). In a special contact zone (50), which is a section of the working surface (19) of the sonotrode (16) and serves to subject at least one connection region (26, 27) to ultrasonic vibrations, the working surface (19) has a surface configuration that differs from a contact zone (30) formed by the remaining working surface (19).

A ultrasonic welding method of joining dissimilar-material workpieces, such as sheet materials, and the joined components formed thereby. The method includes applying ultrasonic energy to a thermoplastic piece to fill a hole of a dissimilar piece to form a weld point that is made up with polymer from the thermoplastic piece. In general, the geometry of the thermoplastic piece is not altered during the process. The dissimilar piece generally has a higher melting temperate and can be metal, thermoset polymers, or other thermoplastic material. The welded pieces can be arranged in a lap, laminate, or double lap configuration. In some embodiments, the hole of the dissimilar sheet material includes undercut features that improve the mechanical interlock between the dissimilar pieces. In some embodiments, the weld point has a mushroom cap to improve mechanical interlock.

A ultrasonic welding method of joining dissimilar-material workpieces, such as sheet materials, and the joined components formed thereby. The method includes applying ultrasonic energy to a thermoplastic piece to fill a hole of a dissimilar piece to form a weld point that is made up with polymer from the thermoplastic piece. In general, the geometry of the thermoplastic piece is not altered during the process. The dissimilar piece generally has a higher melting temperate and can be metal, thermoset polymers, or other thermoplastic material. The welded pieces can be arranged in a lap, laminate, or double lap configuration. In some embodiments, the hole of the dissimilar sheet material includes undercut features that improve the mechanical interlock between the dissimilar pieces. In some embodiments, the weld point has a mushroom cap to improve mechanical interlock.

A first metal member (1) and a second metal member (2) are joined together using a rotary tool (F1D) comprising a base side pin (F3) and a tip side pin (F4), comprising an overlapping and abutting process of forming an overlapped portion (J1a), a top side abutted portion (J1b) and a back side abutted portion (J1c), and a friction stirring process of inserting the tip side pin (F4) that is rotating into the top side abutted portion (J1b) to join the top side abutted portion (J1b) and the overlapped portion (J1a) with a flat face (F5) vertical to a rotation axis of the rotary tool (F1D) being in contact with both the first metal member (1) and the second metal member (2) and with a tip face (f7) of a protruding portion (F6) protruding from the flat face (F5) being inserted deep over the overlapped portion (J1a).

An energy apparatus can be configured for providing energy to an item being transferred over a rotatable drum. The energy apparatus can include a first energy mechanism configured to be fixedly coupled to the rotatable drum and rotate with the rotatable drum. The energy apparatus can also include a second energy mechanism configured to rotate around a circumference of the rotatable drum. The energy apparatus can additionally include a translation system coupled to the second energy mechanism and configured to move the second energy mechanism to an end position that allows the second energy mechanism and the first energy mechanism to provide energy to the item while there is no relative motion between the first energy mechanism and the second energy mechanism. Methods of providing energy to an item utilizing an energy apparatus are also disclosed.

A linear friction welding method capable of accurately controlling a welding temperature and capable of lowering the welding temperature is provided. The present invention is a linear friction welding method comprising: a first step of forming a welded interface by bringing one member into contact with the other member; a second step of repeatedly sliding one member and the other member on the same locus and discharging flash from the welded interface in a state where pressure is applied substantially perpendicularly to the welded interface; and a third step of forming a welded surface by stopping the sliding and setting the pressure to be not less than the yield stress and not more than the tensile strength of one member and/or the other member at a desired welding temperature.

An ultrasonic welding system for a rechargeable battery for mutually welding and bonding includes: a welding apparatus including an anvil and a horn to perform welding and bonding an electrode tab and an electrode lead extending from an electrode assembly of the rechargeable battery through ultrasonic welding by mutually pressing the electrode tab and the electrode lead supplied between the anvil and the horn; and a supply device moves in a vertical or horizontal direction and supplies the electrode lead between the anvil and the horn.

Bulk materials having a kinetically limited nano-scale diffusion bond is provided. The bulk materials having a kinetically limited nano-scale diffusion bond includes transparent material, absorbent opaque material and a diffusion bond. The transparent material has properties that allow an electromagnetic beam of a select wavelength to pass there through without more than minimal energy absorption. The absorbent opaque material has properties that significantly absorb energy from the electromagnetic beam. The diffusion bond is formed by the electromagnetic beam bonding the transparent material to the absorbent opaque material. Moreover, the diffusion bond has a thickness that is less than 1000 nm.

Bulk materials having a kinetically limited nano-scale diffusion bond is provided. The bulk materials having a kinetically limited nano-scale diffusion bond includes transparent material, absorbent opaque material and a diffusion bond. The transparent material has properties that allow an electromagnetic beam of a select wavelength to pass there through without more than minimal energy absorption. The absorbent opaque material has properties that significantly absorb energy from the electromagnetic beam. The diffusion bond is formed by the electromagnetic beam bonding the transparent material to the absorbent opaque material. Moreover, the diffusion bond has a thickness that is less than 1000 nm.

A method of manufacturing a high-pressure fluid vessel includes forming a first portion of a high-pressure fluid vessel with a molding process. The high-pressure fluid vessel includes a stack of capsules. Each capsule includes a first domed end, a second domed end, and a semicylindrical portion extending between and connecting the first domed end to the second domed end. The method further includes forming a second portion of a high-pressure fluid vessel with the molding process. The second portion of the high-pressure fluid vessel is positioned adjacent to the first portion of the high-pressure fluid vessel. The second portion of the high-pressure fluid vessel is welded to the first portion of the high-pressure fluid vessel.