An assembly unit is produced according to the following method steps: an assembly part is provided which does not yet have a through bore. A disc-shaped welding element blank with a first end side, a second end side and a peripheral surface is stamped out of a sheet metal blank by a punch and a hole die so that the peripheral surface has a cylindrical longitudinal portion extending away from the first end side, and an adjoining cone portion which tapers towards the second end side and forms with this a cutting edge. The welding element blank is stamped with the cutting edge at the front into the assembly part to thereby form the through bore.

A connection unit for composites is provided to connect upper and lower plates that overlap each other. The connection unit includes a first connector having a central first downwardly-protruding portion configured to be inserted into an aperture in the upper plate and a peripheral first flange portion, a welding recess being formed in the first protruding portion. Additionally, a second connector has a central second upwardly-protruding portion configured to be inserted into an aperture in the lower plate and a peripheral second flange portion, a welding recess being formed in the second protruding portion. The first and second protruding portions are in contact with each other when inserted into the upper and lower plates, and the contact ends of the first and second protruding portions are welded to each other to secure the upper and lower plates to each other.

An assembly and a method of joining a first part with a second part at an attachment area that includes a localized area on the first part. The localized area is cleaned and activated by a plasma jet. An organosilicon composition is applied by plasma-enhanced chemical vapor deposition to the localized area. An adhesive is applied to the localized area and the second part is mechanically fastened to the first part in the localized area.

A method for manufacturing a riveted joint includes: causing a shaft portion of a steel rivet having the shaft portion and a head portion to pass through through-holes of a plurality of overlaid sheet members; sandwiching the rivet between a pair of electrodes in axial direction of the rivet; applying a force to the rivet and energizing the rivet with the electrodes to form a deformed portion at a distal end of the shaft portion; and cooling the rivet. In the rivet after cooling, a Vickers hardness HB of the head portion satisfies 130HB330, and a Vickers hardness HA of the deformed portion, a thickness TA of the deformed portion, a Vickers hardness HJ of a portion of the shaft portion at center in axial direction and at center in radial direction, diameter DJ of the shaft portion, a Vickers hardness HB of the head portion, and a thickness TB of the head portion satisfy HJDJ4.7HBTB and HATA1.3HBTB.

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:

[00001]$0.001\frac{\mathrm{SR}}{\mathrm{MR}}0.1,$

in particular

[00002]$0.002\frac{\mathrm{SR}}{\mathrm{MR}}0.08,$

wherein SR designates a tip radius of the rounded tip of the welding auxiliary joining part.

A dissimilar-material joined body is obtained by fusion joining a steel material and a stud-equipped aluminum member obtained by attaching a steel stud member to an aluminum material. The stud member includes a head portion and a shaft portion. The shaft portion penetrates the aluminum material in a plate thickness direction, protrudes from the aluminum material, and is formed with, at a tip end of the protruding shaft portion. An expanded diameter portion expands radially outward. A back side surface of the head portion that faces the aluminum material is clinched to the aluminum material. The head portion and the steel material are fusion welded to each other with a gap having a desired interval formed between the aluminum material and the steel material.

A hybrid electrode for resistance spot welding and a method of resistance welding are provided. The hybrid electrode comprises a pin and a collar member. The pin comprises an electrically conductive material and a pin contact surface. The collar member comprises a material that is at least one of less electrically conductive than the electrically conductive material of the pin and less thermally conductive than the electrically conductive material of the pin. The collar member comprises a collar member contact surface, and defines an inner cavity and a longitudinal axis. The pin is at least partially disposed in the inner cavity and the pin contact surface extends away from the collar member and is offset a distance along the longitudinal axis from the collar member contact surface.

A method for manufacturing a riveted joint includes: causing a shaft portion of a steel rivet having the shaft portion and a head portion to pass through through-holes of a plurality of overlaid sheet members; sandwiching the rivet between a pair of electrodes in axial direction of the rivet; applying a force to the rivet and energizing the rivet with the electrodes to form a deformed portion at a distal end of the shaft portion; and cooling the rivet. In the rivet after cooling, a Vickers hardness HB of the head portion satisfies 130HB330, and a Vickers hardness HA of the deformed portion, a thickness TA of the deformed portion, a Vickers hardness HJ of a portion of the shaft portion at center in axial direction and at center in radial direction, diameter DJ of the shaft portion, a Vickers hardness HB of the head portion, and a thickness TB of the head portion satisfy HJDJ4.7HBTB and HATA1.3HBTB.

A securing system, such as a welding system, includes a robot configured to transfer a part to a home position. A securing station has a frame and a gun supported on the frame. The gun includes first and second members movable relative to one another, which are first and second weld gun electrodes, for example. The gun is configured to secure a component to the part in a securing position during a securing operation. A float assembly interconnects the gun to the frame and is configured to permit the gun to glide relative to the welding frame between the home position and the securing position. A homing assembly includes a homing guide configured to release the welding gun from the home position during the securing operation, such as resistance welding fasteners to sheet metal workpieces.

The present disclosure concerns a spot welding method, including the following steps of: arranging two electrically conductive parts to be assembled between two electrodes, each of the two parts having an interface zone between the two parts and a contact zone with one of the two electrodes; establishing a first electric current between the two electrodes through the two parts, the first electric current producing thermal energy capable of forming a weld nugget within the two parts; and adjusting a distribution of the thermal energy density produced by the first electric current based on the intrinsic characteristics of each of the two parts, to generate a weld nugget initiation zone at a selected depth in the parts to be assembled.