An electrical connector for removably engaging a welder to a spot welding tool having a first arm in a pivoting engagement to a second arm. The connector features an electrically conductive member engaged to or forming a powered translating shaft of a welder which is surrounded by a housing. The connector engages within a passage formed in a coupling to communicate forward and rearward movement and electric current to a first arm of a spot welding tool.

The resistance spot welding method includes performing actual welding to squeeze, by a pair of electrodes (14), a sheet combination with a sheet thickness ratio of more than 3 in which a thin sheet (11) is overlapped on at least one face of two or more overlapping thick sheets (12, 13), and passing a current while applying an electrode force to join the sheet combination, wherein in the actual welding, a pattern of the current and the electrode force is divided into two or more steps including a first step and a second step to perform welding, and an electrode force F1 in the first step and an electrode force F2 in the second step satisfy a relationship

F1>F2.

Methods and systems for no-glue pocketed spring unit construction. Rows of pocketed springs, preferably arranged into modules of more than two pocketed springs surrounding a central hole, are ultrasonically welded together when paired vibrating probes and anvils press layers of pocketed spring fabric from the rows of pocketed springs together and a welding pulse is transmitted to the vibrating probe.

A electrical connector for removably engaging a welder to a spot welding tool having a first arm in a pivoting engagement to a second arm. The connector features an electrically conductive member engaged to or forming a powered translating shaft of a welder which is surrounded by a housing. The connector engages within a passage formed in a coupling to communicate forward and rearward movement and electric current to a first arm of a spot welding tool.

A electrical connector for removably engaging a welder to a spot welding tool having a first arm in a pivoting engagement to a second arm. The connector features an electrically conductive member engaged to or forming a powered translating shaft of a welder which is surrounded by a housing. The connector engages within a passage formed in a coupling to communicate forward and rearward movement and electric current to a first arm of a spot welding tool.

An apparatus includes a welding electrode and a holder with a primary electrical connection for carrying a welding current. The electrode and the holder may separate easily due to a weak interference fit of the primary electrical connection. Bare hands may provide sufficient force for separation. The electrode and the holder may be configured for self-alignment. A quick-release mechanism may prevent unintentional dislodgement of the electrode from the holder and include a rotation-resistant device for preventing electrode rotation. A secondary electrical connection may be included to supplement or replace the primary electrical connection. A workpiece clamping force, traditionally intended for clamping the electrode to a workpiece, may also be utilized to enable the secondary electrical connection.

A welding gun is incorporated into a unidirectional welding system, where the unidirectional welding system includes: the welding gun performing welding when a set pressing force is applied; a power portion configured to generate power to be applied to the welding gun; a power connecting portion having one end portion connected to the power portion through a power wire and an opposite end portion engaged with the welding gun; and a power switch provided at the power connecting portion to selectively apply the power generated from the power portion to the welding gun.

A welded assembly and a method of reaction metallurgical welding are disclosed. The assembly includes a first metallic workpiece and a second metallic workpiece attached together by at least two overlapping weld joints. The overlapping weld joints are reaction metallurgically joined (RMJ) weld joints, and each overlapping weld joint overlaps with the other overlapping weld joint by 10-75%. The method of welding includes providing a reactive material between and in contact with the first and second workpieces. In a first position, the workpieces and the reactive material are pressed together, heated, and held between first and second tools to form a first RMJ weld joint between the workpieces. Then, in a second position, the workpieces are pressed together, heated, and held between the tools to form a second RMJ weld joint that overlaps with the first RMJ weld joint.

A stack assembly having a battery tab with a localized weld and method of making the same is disclosed. The assembly is made by a process including the steps of arranging a plurality of battery tabs into a stack assembly; providing a resistive coating on at least one of the interior surfaces and the exterior surfaces of the battery tabs; and resistive heating the stack assembly. The resistive coating is a nickel-phosphorous (NiP) alloy containing 5 to 7 weight percent phosphorus. Resistive heating includes reacting the NiP alloy with an electric current to generate concentrated heat localized between adjacent battery tabs such that the NiP alloy undergoes solid-state bonding with the Cu in the first batter tab.

Methods and systems for no-glue pocketed spring unit construction. Rows of pocketed springs, preferably arranged into modules of more than two pocketed springs surrounding a central hole, are ultrasonically welded together when paired vibrating probes and anvils press layers of pocketed spring fabric from the rows of pocketed springs together and a welding pulse is transmitted to the vibrating probe.