A welding electrode apparatus has a base member and a locking ring for clamping a consumable electrode tip to the electrode base. The base and the tip are predominantly made of copper, or a copper alloy. The base member has a first end that is threaded to fit a welding head that supplies electric current; and an electrically conductive second end to which the electrode tip is mounted. The second portion has an externally facing, axially extending cylindrical wall. A circumferential groove is formed in the wall. The locking ring has a quick-disconnect feature in the form of an array of spring-loaded stainless steel ball bearing detents that deflect to ride upon the cylindrical wall, and spring inwardly to seat in the circumferential groove.

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

A loading pin, for a joining device, having a first axial end portion connectable to an axial drive, and having a second axial end portion which is realized for the purpose of exerting an axial force onto a joining element in order to push the joining element into a holding device and/or in order to support the joining element axially during a joining process, wherein the loading pin comprises an axial hollow channel portion through which a joining element is guidable in an axial feed direction. The loading pin partially defines a lateral joining element feed opening, via which a joining element is feedable into the hollow channel portion.

A welding auxiliary joining part is disclosed in the shape of a stud having a head, a shank and a tip. The welding auxiliary joining part is driven in by means of a mechanical-thermal setting method into a component of non- or poorly weldable material. During the driving in, a welding head is created due to mechanical deformation so that the component may be connected subsequently via the welding auxiliary joining part to a further component of weldable material by means of welding.

An apparatus and method for method for joining materials includes a rivet that may extend through a first sheet to be resistance welded to a second sheet. The head of the rivet has a cavity and vents allowing adhesive extruded from a pilot hole to be received in the cavity and vented in a direction parallel to the first sheet. The rivet is deformed to an hourglass shape that fills the pilot hole and displaces the first sheet into the cavity. Rivet dimension allow for holding with a robotic gripper that can be withdrawn before welding. Methods of monitoring joint quality include comparing welding parameter profiles and images of good and discrepant joints.

A method of securing a fastener to a workpiece includes a fastener that is loaded into a feeder, and an insertion head assembly that is provided adjacent to the feeder. The insertion head assembly includes an insertion actuator that has a movable insertion piston, and a clamp finger that is mounted to the insertion piston. The fastener is arranged beneath a movable fastener joining element that is carried by the insertion head assembly, the workpiece is positioned relative to a locating pin, the insertion head assembly is moved to engage the workpiece with the clamp finger, the fastener is brought into engagement with a locating pin, the fastener joining element is advanced relative to the clamp finger, and the fastener that is secured to the workpiece.

An upper electrode assembly for welding fasteners includes a body that supports an electrode that has an aperture. The aperture is configured to receive a movable pin of a lower electrode assembly arranged opposite the upper electrode assembly. The lower electrode assembly supports a fastener in a welding position. The upper electrode assembly includes a position sensor which includes a position sensor member that is arranged in the body and is configured to cooperate with the pin to detect a fastener welding characteristic.

A method for joining studs to workpieces, in particular for the purpose of stud welding, comprising the steps of acquiring a distinguishing dimension of a stud to be joined by the application of a sensing element to the stud and through measurement of a travel distance of the sensing element as it is applied to the stud; and then joining the stud to a workpiece, if the dimension of the stud is within an allowable tolerance range, and the allowable tolerance range is adapted in dependence on the travel distance of the sensing element measured during a preceding method step.

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.

A bullet trap is disclosed which is formed without intervening sidewalls to enable cross-shooting and the like with reduced risk or ricochet or damage to the bullet trap. Furthermore, the bullet trap can be configured in a variety of ways to eliminate the need for facing plates while providing a removable attachment mechanism, to enable repair on the trap, to reduce bullet adhesion to the trap and to provide improved containment of lead and improved access to the trap.