A system is for bonding a cover sheet to a core to form or repair a dual wall structure. The system includes a cover sheet probe and an inner pedestal probe. A three dimensional contoured tip of the cover sheet probe abuts against a three dimensional contoured outer surface of the cover sheet opposite a pedestal of the core. The pedestal abuts the inner surface of the cover sheet. The inner pedestal probe may be coupled to the core to create a conductive electrical path from the cover sheet probe through at least part of the structure. A flow of electric power is controlled and supplied to the cover sheet probe to heat a junction between the area of the cover sheet abutting the pedestal and the pedestal. A heated area is created in the junction and fixedly couples the coversheet and the pedestal.

A method of making a connector assembly includes attaching two stamped housing sections together to form a connector housing having a housing groove with a groove bottom and two side walls and providing the connector housings with a spring used as a mechanical connector and/or as an electrical connector for numerous applications and across numerous industries. The groove geometries can easily be altered using different stamping dies.

A method of making a connector assembly includes attaching two stamped housing sections together to form a connector housing having a housing groove with a groove bottom and two side walls and providing the connector housings with a spring used as a mechanical connector and/or as an electrical connector for numerous applications and across numerous industries. The groove geometries can easily be altered using different stamping dies.

A method of making a connector assembly includes attaching two stamped housing sections together to form a connector housing having a housing groove with a groove bottom and two side walls and providing the connector housings with a spring used as a mechanical connector and/or as an electrical connector for numerous applications and across numerous industries. The groove geometries can easily be altered using different stamping dies.

A method of making a connector assembly includes attaching two stamped housing sections together to form a connector housing having a housing groove with a groove bottom and two side walls and providing the connector housings with a spring used as a mechanical connector and/or as an electrical connector for numerous applications and across numerous industries. The groove geometries can easily be altered using different stamping dies.

A spot welding apparatus includes a spot welding gun and a welding gun control apparatus. The welding gun control apparatus includes a pressurizing force control part controlling the pressurizing force, a position control part controlling the position of at least one electrode, and a determination part determining whether or not the welding is performed in a normal state. The position control part controls an electrode drive motor so as to hold the electrodes, after the supply of the electric current is started, at positions when the initial pressurizing force is applied before the electric current is supplied. The determination part acquires the pressurizing force and determines whether or not the welding is performed in a normal state based on change tendency in the pressurizing force.

A method to join three panels together for a motor vehicle includes one or more of the following: layering the three panels, the three panels including a first panel, a second panel, and a third panel, the second panel being positioned between the first panel and the third panel, the third panel having a higher electrical conductivity than the first panel and the second panel; joining the first panel and the second panel together; and joining the third panel to the first panel and the second panel.

A method for welding a stack of sheets having a plurality of sheets of different materials is provided. In an aspect, the stack of sheets includes an aluminum sheet and a galvanneal steel sheet. In an aspect, the method includes resistively spot welding the galvanneal sheet to a hot-stamped steel sheet placed between the aluminum sheet and the galvanneal sheet, the sheet of hot-stamped steel including stress relief sections. The method further includes placing a metal foil on the aluminum sheet and vaporizing the metal foil to project portions of the aluminum sheet through the stress relief sections of the hot-stamped steel sheet to weld the portions of the aluminum sheet to the galvanized steel sheet. In another aspect, the method includes placing the metal foil on a raised portion of the aluminum sheet and projecting the raised portion of the aluminum onto the galvanneal steel sheet.

Aluminum-base alloy workpieces have surfaces with films of aluminum oxide which inhibit good contact with weld faces of resistance spot weld electrodes and the faying surfaces of, for example, sheet workpieces stacked for welding. Sometimes, the surfaces of the sheets also are coated with an adhesive or a sealer which further complicates welding. But in accordance with this invention, weld faces of opposing, round, copper welding electrodes are pressed against opposite outside surfaces of the sheets at a spot weld site and weld current is applied to the electrodes in accordance with a three-stage weld schedule to better form each weld. The weld schedule comprises a Conditioning stage (stage 1), a weld nugget Shaping stage (stage 2), and a weld nugget Sizing stage (stage 3).

A bonding probe is used for bonding a cover sheet to a core to form or repair a dual wall structure. The bonding probe includes a body, an attachment end at a distal end of the body, a head at an opposite end of the body, a tip extending from the head, and a cooling passageway. The attachment end couples the body to a resistance welder. The tip extends to form a proximate end of the body. The tip includes a contacting area having a predetermined three dimensional contoured surface. The contacting area aligns with a predetermined area of a three dimensional outer surface of a cover sheet of a dual walled structure. The cooling passageway provides a passageway for a flow of cooling fluid. The cooling passageway extends through the head, and into the tip.