A different material joining method sandwiches, with electrodes, a first joining member and a second joining member lower in melting point than the first member, applies pressure and electricity to them, and joins them in preset joint parts. The method includes forming a discontinuous abutting part beforehand in the joint part of at least one of the two members. The two members abut onto the abutting part in a discontinuous state. The method includes melting the second member by sandwiching the joint parts with the electrodes and applying pressure and electricity on the joint parts in a state where the two members abut onto each other in the joint parts while the abutting part is included. The method includes welding both the members by bringing a melting material of the second member into interface joining with a surface of the first member toward the second member.

A different material joining method sandwiches, with electrodes, a first joining member and a second joining member lower in melting point than the first member, applies pressure and electricity to them, and joins them in preset joint parts. The method includes forming a discontinuous abutting part beforehand in the joint part of at least one of the two members. The two members abut onto the abutting part in a discontinuous state. The method includes melting the second member by sandwiching the joint parts with the electrodes and applying pressure and electricity on the joint parts in a state where the two members abut onto each other in the joint parts while the abutting part is included. The method includes welding both the members by bringing a melting material of the second member into interface joining with a surface of the first member toward the second member.

An apparatus and method for fastening dissimilar materials like steel, plastic and aluminum. A resistance welding fastener having multiple layers may be used with or without a sealant. The fastener may be used to form an aluminum covered steel laminate via a hemming pattern of attachment. The fastener may have a solid shaft or have an extended reach and have features for interacting with the welding electrode. A variety of electrode tips may be employed to cooperate with the fastener.

An apparatus and method for fastening dissimilar materials like steel, plastic and aluminum. A resistance welding fastener having multiple layers may be used with or without a sealant. The fastener may be used to form an aluminum covered steel laminate via a hemming pattern of attachment. The fastener may have a solid shaft or have an extended reach and have features for interacting with the welding electrode. A variety of electrode tips may be employed to cooperate with the fastener.

Provided is a method for joining two dissimilar metal plates having different volume resistivity to increase joint strength of the metal plates. The method includes: overlapping a first metal plate including a first metal and a second metal plate including a second metal, the second metal having volume resistivity higher than the first metal and being different from the first metal, and bringing a pair of electrodes into contact with a surface of an overlapped portion of the first metal plate that is overlapped with the second metal plate; and applying current between the electrodes so as to melt the first metal present at a current-flowing region of the overlapped portion due to heat generated by resistance to form an intermetallic compound of the first and the second metals between the first and the second metal plates and join the first and the second metal plates via the intermetallic compound.

A method for joining two dissimilar metal plates having different volume resistivity with enhanced joint strength. The method includes overlaying a first metal plate made of first metal and a second metal plate made of second metal with higher volume resistivity and higher melting point in comparison with the first metal, bringing a pair of electrodes into contact with the surface of a portion of the second metal plate overlapping the first metal plate, supplying current between the electrodes so as to resistance-heat the second metal present in a current-flowing region to a temperature lower than the melting point of the second metal and higher than the melting point of the first metal, thereby partially melting the first metal plate with the heat so that an intermetallic compound is generated between the first and second metal plates, and thus joining the first and second metal plates via the intermetallic compound.

A method for joining two dissimilar metal plates having different volume resistivity with enhanced joint strength. The method includes overlaying a first metal plate made of first metal and a second metal plate made of second metal with higher volume resistivity and higher melting point in comparison with the first metal, bringing a pair of electrodes into contact with the surface of a portion of the second metal plate overlapping the first metal plate, supplying current between the electrodes so as to resistance-heat the second metal present in a current-flowing region to a temperature lower than the melting point of the second metal and higher than the melting point of the first metal, thereby partially melting the first metal plate with the heat so that an intermetallic compound is generated between the first and second metal plates, and thus joining the first and second metal plates via the intermetallic compound.

A new weld configuration is used to obtain a robust and consistent resistance weld between the tabs of an anode current collector and the casing of an electrochemical cell. This is done by adding a resistive transferable electrode tip between at least one of the welding electrodes, preferably the movable welding electrode, and the stacked parts that are being joined together. The purpose of the transferable electrode tip is to generate a sufficient amount of heat during the welding process so that the stacked parts are joined together without adding any product functionality. In one embodiment of the present invention, the transferrable electrode tip is a stainless-steel ball, the stacked anode current collector tabs are of nickel, and the cell casing is of stainless-steel.

A new weld configuration is used to obtain a robust and consistent resistance weld between the tabs of an anode current collector and the casing of an electrochemical cell. This is done by adding a resistive transferable electrode tip between at least one of the welding electrodes, preferably the movable welding electrode, and the stacked parts that are being joined together. The purpose of the transferable electrode tip is to generate a sufficient amount of heat during the welding process so that the stacked parts are joined together without adding any product functionality. In one embodiment of the present invention, the transferrable electrode tip is a stainless-steel ball, the stacked anode current collector tabs are of nickel, and the cell casing is of stainless-steel.

Disclosed are a joining structure of different kinds of conductors, a joining method of different kinds of conductors, and a joint of power cables capable of improving joining reliability of a junction of the different kinds of conductors.