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 for manufacturing a composite article from a composite material. The apparatus comprising: a pulsed broadband radiation source comprising a flashlamp and a light guide adapted to guide light emitted by the pulsed broadband radiation source to a target area. The light guide comprises at least a portion ahead of the pulsed broadband radiation source, relative to the target area, comprising a light transmitting material.

A weld stud including a shank that has a reduced diameter portion, and a larger diameter portion. A weld base is defined on the reduced diameter portion and a flange is positioned on the larger diameter portion. A bore wall extends axially through a face of the flange and into the larger diameter portion. The bore wall has a threaded portion that has a threaded diameter for receiving a fastener. A base diameter of the weld base is smaller than a larger diameter of the larger diameter portion and substantially equal to, or smaller than the threaded diameter. The threaded portion is axially spaced from the face of the flange by a first unthreaded portion, which defines a first unthreaded diameter that is larger than the threaded diameter. These features limit the loads transmitted to the fastener, thus allowing the weld stud to withstand shock loads to prevent fastener failures.

An apparatus and method for fastening layers of non-ferrous alloys, like aluminum, magnesium and copper utilizes a steel fastener and a spot welding machine. The fastener and metals are stacked and the heat from the welder's electric current softens the lower melting point aluminum allowing the fastener to penetrate the aluminum. A weld zone between the fastener and the various layers creates an internal weld. The fastener has a rough shaft that is coated by the molten weld zone and is hard to withdraw on solidification. Layers of non-conductive materials like plastics and ceramics may also be affixed to a conductive layer using a fastener made from a compatible material that extends through a pilot hole and welds to or penetrates a conductive layer. The fastener may have projections that initially reduce contact area with the stack.

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.

An ultra high-strength flux-cored arc welded joint having excellent impact toughness comprises: 0.01 wt % to 0.06 wt % of carbon (C), 0.1 wt % to 0.5 wt % of silicon (Si), 1.5 wt % to 3.0 wt % of manganese (Mn), 2.5 wt % to 3.5 wt % of nickel (Ni), 0.5 wt % to 1.0 wt % of molybdenum (Mo), 0.4 wt % to 1.0 wt % of copper (Cu), 0.4 wt % to 1.0 wt % of chromium (Cr), 0.01 wt % to 0.1 wt % of titanium (Ti), 0.003 wt % to 0.007 wt % of boron (B), 0.001 wt % to 0.006 wt % of nitrogen (N), 0.02 wt % (excluding 0) or less of phosphorus (P), 0.01 wt % (excluding 0) or less of sulfur (S), 0.03 wt % to 0.07 wt % of oxygen (O), and remaining iron (Fe) as well as unavoidable impurities.

A method of resistance spot welding a steel workpiece and an aluminum or aluminum alloy (aluminum) workpiece together includes several steps. One step involves providing a workpiece stack-up with a steel workpiece and an aluminum workpiece. Another step involves attaching a cover over a weld face of a welding electrode. The cover is made of a metal material with an electrical resistivity that is greater than an electrical resistivity of a material of the welding electrode. Yet another step involves performing multiple individual resistance spot welds to the workpiece stack-up. The cover abuts the aluminum workpiece while the individual resistance spot welds are performed. And another step involves removing the cover from the welding electrode after the individual spot welds are performed.

A mounting bolt for a sub-frame is disclosed. A mounting bolt for a sub-frame that is used to engage a sub-frame to a front side member of a vehicle according to one or a plurality of exemplary embodiments of the present invention may include a bolt body that is inserted into a penetration hole of a mounting bracket fixed on the front side member and is joined to the mounting bracket through a first flange that is formed at an upper end circumference thereof, a support body at which a second flange is formed at a lower end circumference to have a hollow space and is disposed on the bolt body, and a joining plate that is interposed between the first flange and the second flange and is welded with a first join protrusion that is formed on an upper surface of the first flange and a second join protrusion that is formed on a lower surface of the second flange by electrical resistance.

A welded structural assembly and method are provided, which in one form includes at least one upper substrate, at least one lower substrate disposed adjacent the upper substrate, and a fastener extending through the upper substrate and into the lower substrate. The fastener is welded to the lower substrate and defines a head portion having an outer periphery and an underside. A sealing member is disposed under the head portion and contacts the underside thereof, and further extends beyond the outer periphery of the head portion.

Provided are a welded joint of extremely low-temperature steel and flux cored, submerged, and gas metal arc welding materials which can be used to prepare the welded joint, wherein the welded joint of extremely low-temperature steel has outstanding impact toughness in extremely low-temperature conditions and excellent yield strength at room temperature.