A method of inserting a rivet into a workpiece comprises moving the rivet and workpiece relative to one another, along a longitudinal axis of the rivet, so as to drive the rivet into the workpiece. The rivet is rotated about its longitudinal axis, relative to the workpiece, for at least part of the time during which it is in contact with the workpiece. The speed of said rotation, or the speed of movement along the longitudinal axis of the rivet, is altered at least once before driving of the rivet into the workpiece is complete. One axial end of the rivet has a tip for piercing the workpiece, and the rivet has a substantially cylindrical shank extending longitudinally from the tip. The shank has one or more surface irregularities.

Aluminum alloy workpieces and/or magnesium alloy workpieces are joined in a solid state weld by use of a reactive material placed, in a suitable form, at the joining surfaces. Joining surfaces of the workpieces are pressed against the interposed reactive material and heated. The reactive material alloys or reacts with the workpiece surfaces consuming some of the surface material in forming a reaction product comprising a low melting liquid that removes oxide films and other surface impediments to a welded bond across the interface. Further pressure is applied to expel the reaction product and to join the workpiece surfaces in a solid state weld bond.

A power module substrate includes a circuit layer, an aluminum layer arranged on a surface of an insulation layer, and a copper layer laminated on one side of the aluminum layer. The aluminum layer and the copper layer are bonded together by solid phase diffusion bonding.

The present disclosure provides a wire and arc additive manufacturing (WAAM) method for a magnesium alloy. The method includes the following steps: step 1: performing a WAAM process assisted by cooling and rolling; step 2: milling side and top surfaces of an additive part; step 3: performing, by friction stir processing (FSP) equipment, an FSP process on the additive part, and applying cooling and rolling to a side wall of the additive part through a cooling and rolling device during the FSP process; step 4: finish-milling the top surface of the additive part for a WAAM process in the next step; and step 5: repeating the above steps cyclically until final forming of the part is finished. The present disclosure completely breaks dendritic structures and refines grains in the WAAM process of the magnesium alloy, thereby effectively repairing defects such as pores and cracks.

The present disclosure provides methods for preparing an extruded product from a solid billet. The methods can include providing an as-cast billet for extrusion; applying a simultaneous rotational shear and axial extrusion force to the as-cast billet to plasticize the as-cast billet; and extruding the plasticized as-cast billet with an extrusion die to form an extruded product. Methods for preparing extruded products from billets can also include: providing a billet for extrusion; while maintaining a majority of the billet below 100° C., applying a simultaneous rotational shear and axial extrusion force to one end of the billet to plasticize the one end of the billet; and extruding the plasticized one end of the billet with an extrusion die to form an extruded product. Methods for preparing an extruded product from a billet can also include providing a billet for extrusion; applying a simultaneous rotational shear and axial extrusion force to the billet to plasticize the billet; extruding the plasticized billet with an extrusion die to form an extruded product; and artificially aging the extruded product for less than the ASTM recommended amount of time.

Methods for processing a metal substrate for use in a power electronics device are provided. In one example, the method includes placing a metal substrate on a support associated with a laser system. The method includes performing a pulsed laser treatment process on at least a portion of the surface of the metal substrate. The pulsed laser treatment process exposes the at least a portion of the surface of the metal substrate to a plurality of laser pulses to modify a surface roughness of the at least a portion of the surface of the metal substrate. After performing the pulsed laser treatment process, the method includes creating a metallized interface for coupling an electrical component to the metal substrate at the at least a portion of the surface of the metal substrate.

An electric cable includes a terminal, and a manufacture method thereof is to suppress shedding of wire strands from a core wire. The electric cable with terminal includes an end of an electric cable connected to the terminal. The electric cable includes a core wire that is a bundle of a plurality of wire strands. The terminal includes a connection portion in which the core wire is exposed at the end of the electric cable. The core wire is placed on the connection portion including a welded portion that is to be ultrasonic welded to the connection portion. The welded portion includes a high compression portion in which the core wire is compressed, and a low compression portion in which a position that is closer than the high compression portion to the end of the core wire is compressed at a compression lower than that of the high compression portion.

Disclosed are a joint of a copper terminal and an aluminium conductor and an ultrasonic welding method thereof. One spacing metal layer is added between the copper terminal and the aluminium conductor, and firstly, the spacing metal layer is fixed at a welding end of a base material by means of a manner such as electroplating, pressure welding, electric arc spray welding or electromagnetic welding, and the three parts are then welded together by means of an ultrasonic welding manner. The welding method is suitable for the welding of various joints, the electrochemical corrosion resulting from the potential difference between the copper and aluminium electrodes can be effectively reduced, and the mechanical properties of the joint can be improved.

An encapsulation structure of a power module is disclosed in this application, which includes a power module and a liquid cooler. The power module includes a power module body, a metal baseplate, and heat dissipation finned tubes. A front side of the metal baseplate is connected to the power module body, and a back side of the metal baseplate is connected to the heat dissipation finned tubes. The metal baseplate has a protrusion part protruding. There are a plurality of grooves on a fluid pipe of the liquid cooler, a cavity exists between two adjacent grooves of the plurality of grooves, and the cavity is configured to communicate the two adjacent grooves. The power module body is lapped on the groove, a back side of the protrusion part is in contact with an edge surface of the groove, and the heat dissipation finned tubes are placed in the groove.

Electrical connection console for a motor vehicle board net comprising a cable 2 with a metallic stranded conductor 4, and an electrical tap electrically and mechanically connected to the stranded conductor 4, characterized in that the tap is formed from a metallic sleeve 10, in that the sleeve 10 is connected to the stranded conductor 4 in a connection region 8 of the stranded conductor 4, and in that the sleeve 10 has a longitudinal extent in a longitudinal axis parallel to a longitudinal axis of the stranded conductor 4, in that the sleeve 10 has a recess 26 whose longitudinal axis runs transversely with respect to the longitudinal axis of the sleeve 10, and in that a contact sleeve 28 is arranged in the recess 26.