A steel plate frame and a thin plate are made of different materials. A plurality of through holes are formed in a portion of the thin plate to be placed on the steel plate frame. A plurality of projections 6c are formed on a support plate, each of the projections being allowed to be inserted into a corresponding one of the through holes. An adhesive is applied to a portion of the steel plate frame on which the thin plate is placed. The thin plate is placed on the steel plate frame, and the steel plate frame and the thin plate are bonded together by the adhesive. The support plate is placed on the thin plate to insert the projections into the through holes. The projections and the steel plate frame are welded to form a plurality of welded spots.

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.

To accurately make a dressing quality determination based on resistance waveforms, a dressing quality determination method determines the quality of dressing performed for electrodes when resistance welding is performed at a plurality of welding points. This method includes accumulating a known resistance waveform immediately after dressing the electrodes, and a known resistance waveform immediately before dressing the electrodes; creating, by a statistical method, a model for setting a threshold value for dressing quality determination, based on a plurality of known resistance waveforms immediately after dressing and a plurality of known resistance waveforms immediately before dressing; acquiring an unknown resistance waveform immediately after dressing the electrodes; and determining whether dressing is normal or dressing is abnormal by comparing the unknown resistance waveform immediately after dressing with the threshold value for dressing quality determination.

To accurately make a dressing quality determination based on resistance waveforms, a dressing quality determination method determines the quality of dressing performed for electrodes when resistance welding is performed at a plurality of welding points. This method includes accumulating a known resistance waveform immediately after dressing the electrodes, and a known resistance waveform immediately before dressing the electrodes; creating, by a statistical method, a model for setting a threshold value for dressing quality determination, based on a plurality of known resistance waveforms immediately after dressing and a plurality of known resistance waveforms immediately before dressing; acquiring an unknown resistance waveform immediately after dressing the electrodes; and determining whether dressing is normal or dressing is abnormal by comparing the unknown resistance waveform immediately after dressing with the threshold value for dressing quality determination.

A gas diffusion electrode for a membrane electrode assembly is provided with expanded metal layers each having a mesh configuration defining a length orientation of the expanded metal layers. The expanded metal layers each have opposed flat sides and are stacked in a layered arrangement such that the flat sides of the expanded metal layers that are neighboring each other in the layered arrangement are facing each other as facing flat sides, respectively. The facing flat sides are connected to each other by pulsed resistance welding at welded contact points. Due to the mesh configuration, the welded contact points are distributed evenly across the entire surface area of the facing flat sides. At least one of the expanded metal layers is oriented with its length orientation so as to be rotated by 90° relative to the length orientation of one of the neighboring expanded metal layers.

A gas diffusion electrode for a membrane electrode assembly is provided with expanded metal layers each having a mesh configuration defining a length orientation of the expanded metal layers. The expanded metal layers each have opposed flat sides and are stacked in a layered arrangement such that the flat sides of the expanded metal layers that are neighboring each other in the layered arrangement are facing each other as facing flat sides, respectively. The facing flat sides are connected to each other by pulsed resistance welding at welded contact points. Due to the mesh configuration, the welded contact points are distributed evenly across the entire surface area of the facing flat sides. At least one of the expanded metal layers is oriented with its length orientation so as to be rotated by 90° relative to the length orientation of one of the neighboring expanded metal layers.

In a vehicle body rear part structure, a plurality of first spot weld parts that join the rear panel inner flange and the rear panel outer flange by spot welding are provided at a first weld pitch; a plurality of second spot weld parts that join together the rear pillar inner flange and the rear pillar outer flange by spot welding are provided at a second weld pitch; at the corner part, a plurality of third spot weld parts that join together, by spot welding, regions of the rear panel inner flange, the rear panel outer flange, the rear pillar inner flange, and the rear pillar outer flange where at least three of the flanges overlap with one another are provided at a third weld pitch; and the third weld pitch is set to be shorter than the first weld pitch and the second weld pitch.

In a vehicle body rear part structure, a plurality of first spot weld parts that join the rear panel inner flange and the rear panel outer flange by spot welding are provided at a first weld pitch; a plurality of second spot weld parts that join together the rear pillar inner flange and the rear pillar outer flange by spot welding are provided at a second weld pitch; at the corner part, a plurality of third spot weld parts that join together, by spot welding, regions of the rear panel inner flange, the rear panel outer flange, the rear pillar inner flange, and the rear pillar outer flange where at least three of the flanges overlap with one another are provided at a third weld pitch; and the third weld pitch is set to be shorter than the first weld pitch and the second weld pitch.

A method for resistance welding a metallic component to a sandwich metal sheet with a thermoplastic layer disposed between two metallic cover layers may involve heating a region of the sandwich metal sheet to be welded such that the thermoplastic layer softens, displacing the thermoplastic layer from the region by compressing the cover layers, and welding the cover layers with the metallic component by means of a flow of electrical current in a first circuit via a first welding electrode disposed on a side of the sandwich metal sheet and a second welding electrode disposed on a side of the metallic component. The method for resistance welding has short cycle times, and a compact design and a process-reliable welded connection can be achieved. The method may further involve heating the region to be welded by a flow of current in a second circuit comprising the first welding electrode and an electrical conductor disposed between the first welding electrode and the sandwich metal sheet.”