A metallic member bonding device includes a pressurizing unit, a current supply unit, and a deformation suppressing unit. The pressurizing unit pressurizes a first metallic member toward a hole portion of a second metallic member to press the first metallic member therein. The current supply unit supplies a welding current between the first metallic member and the second metallic member. The deformation suppressing unit suppresses deformation of one of the first metallic member and the second metallic member, the one member having a constituent metallic material with at least one of a proof stress and a melting temperature lower than that of the other member, the deformation being in a direction of a cross section crossing a direction of the press-in. Then, the deformation suppressing unit is provided in a region covering at least a plastic flow range in the press-in direction.

A method of joining a first piece of an automotive component that is made from a first material to a second piece of the automotive component that is made from a second material includes machining a fay surface onto each of the first and second pieces of the automotive component, cleaning the fay surfaces of each of the first and second pieces of the automotive component, placing a metal filler between the fay surfaces of the first and second pieces of the automotive component, holding the first and second pieces together with the metal filler positioned between the fay surfaces of the first and second pieces, and passing an electric current through the first piece, the metal filler and the second piece to melt the metal filler and weld the first piece to the second piece.

A method of joining a first piece of an automotive component that is made from a first material to a second piece of the automotive component that is made from a second material includes machining a fay surface onto each of the first and second pieces of the automotive component, cleaning the fay surfaces of each of the first and second pieces of the automotive component, placing a metal filler between the fay surfaces of the first and second pieces of the automotive component, holding the first and second pieces together with the metal filler positioned between the fay surfaces of the first and second pieces, and passing an electric current through the first piece, the metal filler and the second piece to melt the metal filler and weld the first piece to the second piece.

A metal joined body has an iron base body and an aluminum base body that are joined together via a joint layer. The joint layer has a first layer composed of a first intermetallic compound formed on the iron base body side and a second layer composed of a second intermetallic compound formed on the aluminum base body side. The first layer has one or more first protrusions that merge integrally into the iron base body and extend in a pile shape into the first intermetallic compound. The second layer may have one or more second protrusions that are composed of a second intermetallic compound and extend in a columnar shape into the aluminum base body. The first intermetallic compound may contain Al.sub.5Fe.sub.2, and the second intermetallic compound may contain Al.sub.3Fe. The total thickness of the first layer and the second layer is, for example, 2 to 15 μm.

A method for joining of at least two materials, non-weldable directly to each other with thermal joining processes in a lap joint configuration includes a two step sequence including a first step to apply a thermomechanical or mechanical surface protection layer on the surface of a (stainless) steel substrate and a second step where, a thermal joining process is used to weld the sprayed layer with an applied aluminum sheet without having brittle intermetallic phases in the whole material configuration.

A method for joining of at least two materials, non-weldable directly to each other with thermal joining processes in a lap joint configuration includes a two step sequence including a first step to apply a thermomechanical or mechanical surface protection layer on the surface of a (stainless) steel substrate and a second step where, a thermal joining process is used to weld the sprayed layer with an applied aluminum sheet without having brittle intermetallic phases in the whole material configuration.

A system for increasing joint strength and reducing embrittlement in a resistance spot weld of metal workpieces is disclosed. The system comprises a stackup of first and second metal workpieces, and an interface member disposed between the first and second metal workpieces. The interface member comprises a peripheral wall defining a hollow inner portion. The peripheral wall has a first open end extending to a second open end. The first open end is in contact with the first metal workpiece defining a first weld portion thereon. The second open end is in contact with the second metal workpiece defining a second weld portion thereon. The system further comprises a first electrode configured to contact the first metal workpiece to heat the peripheral wall at the first weld portion and join the first metal workpiece with the first open end of the peripheral wall. The system further comprises a second electrode configured to contact the second metal workpiece to heat the peripheral wall at the second weld portion and join the second metal workpiece with the second open end of the peripheral wall to define a weld joint. The system further comprises a power source configured to power the first and second electrodes and a controller configured to control the power to the first and second electrodes to heat the peripheral wall.

A system for increasing joint strength and reducing embrittlement in a resistance spot weld of metal workpieces is disclosed. The system comprises a stackup of first and second metal workpieces, and an interface member disposed between the first and second metal workpieces. The interface member comprises a peripheral wall defining a hollow inner portion. The peripheral wall has a first open end extending to a second open end. The first open end is in contact with the first metal workpiece defining a first weld portion thereon. The second open end is in contact with the second metal workpiece defining a second weld portion thereon. The system further comprises a first electrode configured to contact the first metal workpiece to heat the peripheral wall at the first weld portion and join the first metal workpiece with the first open end of the peripheral wall. The system further comprises a second electrode configured to contact the second metal workpiece to heat the peripheral wall at the second weld portion and join the second metal workpiece with the second open end of the peripheral wall to define a weld joint. The system further comprises a power source configured to power the first and second electrodes and a controller configured to control the power to the first and second electrodes to heat the peripheral wall.

Methods of fastening are provided. A method comprises contacting a fastener with a first layer of an assembly at a first location. The assembly comprises the first layer, a third layer, and a second layer positioned intermediate the first layer and the third layer. The first layer, the third layer, and the fastener are electrically conductive. The second layer defines a gap and the first location is in communication with the gap. Electrical communication is formed between the assembly and the fastener. The first layer is fastened to the third layer through the gap in the second layer with the fastener. The fastening comprises resistance welding the fastener to the third layer.

Methods of fastening are provided. A method comprises contacting a fastener with a first layer of an assembly at a first location. The assembly comprises the first layer, a third layer, and a second layer positioned intermediate the first layer and the third layer. The first layer, the third layer, and the fastener are electrically conductive. The second layer defines a gap and the first location is in communication with the gap. Electrical communication is formed between the assembly and the fastener. The first layer is fastened to the third layer through the gap in the second layer with the fastener. The fastening comprises resistance welding the fastener to the third layer.