A method of joining a multiple member work-piece includes providing a first steel work-piece having a first electrical resistivity and a second steel work-piece having a second electrical resistivity that is lower than the first electrical resistivity. A third material is disposed in contact with the second steel work-piece. The third material has an electrical resistivity that is greater than the second electrical resistivity. The method includes resistance welding the first and second work-pieces together. The third material may be in the form of a rivet, a third work-piece, or a coating material disposed between the first and second work-pieces. A bonded assembly includes steel members and a third material being bonded together, wherein the electrical resistivity of the second member is lower than the electrical resistivity of the first member, and the third material has an electrical resistivity that is greater than the electrical resistivity of the second member.

A method of joining a multiple member work-piece includes providing a first steel work-piece having a first thickness and a second steel work-piece having a second thickness. The first thickness is at least twice the second thickness. A third material is disposed in contact with the second steel work-piece. For example, the third material may be in the form of a rivet, a plurality of pins, or a coating material. The method includes resistance welding the first and second work-pieces together. A bonded assembly includes the first and second steel members and the third material being bonded together, where the thickness of the first member is at least twice the thickness of the second member.

A weld rivet for use in a method of resistance element welding of dissimilar materials includes a shank portion, a cap portion, and a coating. The shank portion has a cylindrical shape, a first end, and a second end opposite the first end. The cap portion has a flat disc shape, a top surface, and a bottom surface. The bottom surface of the cap portion is disposed on the first end of the shank portion. The coating is disposed on the bottom surface of the cap portion. The coating electrically insulates the cap portion.

Resistance spot rivet welding systems, subsystems, and methods of use thereof are provided.

A pierce metal includes a head and a shaft. The shaft is configured to penetrate through an aluminum die-cast member with a protruded tip surface of the shaft being exposed from the aluminum die-cast member, and an outer peripheral surface of the shaft is configured to come into contact with a through-hole of the aluminum die-cast member, upon joining the aluminum die-cast member and the iron-based member together. The head and the iron-based member in contact with the protruded tip surface are configured to be held under pressure and applied with electric power by weld electrodes to perform spot welding of the protruded tip surface and the iron-based member, upon joining the aluminum die-cast member and the iron-based member together. The outer peripheral surface includes a non-contact part configured to come into non-contact with the through-hole in a state in which the shaft is penetrated through the aluminum die-cast member.

A method for manufacturing a shunt resistor is described. In this method, a first electrode plate and a second electrode plate are provided. The first electrode plate includes a first carrying portion having a first hole. The second electrode plate includes a second carrying portion having a second hole. A resistor plate is placed between the first and second electrode plates. The resistor plate has a first through hole and a second through hole respectively on the first hole and the second hole. A first rivet is pressed into the first through hole and the first hole. A second rivet is pressed into the second through hole and the second hole. Current is applied to the first rivet and the second rivet to weld the first rivet, the first electrode plate and the resistor plate, and to weld the second rivet, the second electrode plate and the resistor plate.

The present invention describes an element supply device of a setting welding device for a bolt-like welding auxiliary joining part with head and shaft. This element supply device comprises two scissor-like arranged clamping jaw levers which define a blind hole channel with a nest-like end position for receiving the welding auxiliary joining part. Further, the element supply device comprises a first actuator and a second actuator by means of which the nest-like end position can be positioned suitably with respect to an electrode punch.

The disclosure is related to various connecting methods for a welding auxiliary joining part having a head and a rounded tip for setting in at least one first component having a die as counter-bearing, which has a concave recess with an inner wall having at least in sub-areas an arc shape and having a matrix radius MR in the range from 1.0 mmMR60 mm, for preparing a subsequent welding method. The geometry of the welding auxiliary joining part and the die meet the following condition: $0.001\frac{\mathrm{SR}}{\mathrm{MR}}0.1,$
in particular $0.002\frac{\mathrm{SR}}{\mathrm{MR}}0.08,$
wherein SR designates a tip radius of the rounded tip of the welding auxiliary joining part.

A welded structural assembly and method, in one form, includes an upper substrate, a lower substrate adjacent the upper substrate, a fastener, and a sealing member. The fastener includes a shank portion, a first head portion, and a second head portion. The shank portion extends through the upper substrate and into the lower substrate. The shank is welded to the lower substrate. The first head portion has an outer periphery and an underside. The second head portion is frangibly coupled to the first head portion. The sealing member is disposed under the first head portion between the upper substrate and the first head portion. The sealing member contacts the underside and extends beyond the outer periphery such that the sealing member extends radially outward beyond all points of the first head portion.

A collet assembly including an actuator and a collet connected to the actuator. The collet assembly is adapted to be installed on a welding electrode holder having an electrode. The collet is moveable by the actuator from an advanced position, in which the collet is adapted to grip a fastener such as a welding rivet, and a retracted position, in which at least a portion of the collet is retracted into the actuator to enable the electrode to engage the fastener for welding to a work piece, and the collet is adapted to release the fastener.