Electrodes for resistance welding and method of use thereof

Patent metadata

Field	Value
Publication number	US-12365045-B2
Application number	US-202117479816-A
Country	US
Kind code	B2
Filing date	Sep 20, 2021
Priority date	Sep 21, 2020
Publication date	Jul 22, 2025
Grant date	Jul 22, 2025

Abstract

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.

First claim

What is claimed is:

1. A hybrid electrode for resistance spot welding, the hybrid electrode comprising:
a pin comprising an electrically conductive material, the pin comprising a pin contact surface and a base; and
a collar member comprising 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, wherein the collar member comprises a first collar end, a second collar end, a collar member contact surface and defines an inner cavity and a longitudinal axis, wherein the inner cavity extends from the first collar end to the second collar end;
wherein the pin extends through 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, and wherein the collar member is intermediate the base and the pin contact surface; and

wherein the collar member is configured to directly contact a surface of an assembly contacted by the pin to limit a penetration depth of the hybrid electrode into the assembly during a resistance spot welding operation;
wherein the pin contact surface is configured to directly contact the assembly during a resistance spot welding operation;
wherein the material of the collar member comprises at least one of copper, a copper alloy, iron, an iron alloy, titanium, and a titanium alloy.

2. The hybrid electrode of claim 1 , wherein the collar member is less electrically conductive than the electrically conductive material of the pin.

3. The hybrid electrode of claim 1 , wherein the collar member is less thermally conductive than the electrically conductive material of the pin.

4. The hybrid electrode of claim 1 , wherein the pin comprises at least one of copper and a copper alloy.

5. The hybrid electrode of claim 1 , wherein the pin and the collar member are secured together by a friction fit, a braze, or a combination thereof.

6. The hybrid electrode of claim 1 , wherein the collar member comprises an external diameter in a range of 5 mm to 25 mm and the pin comprises an external diameter in a range of 1 mm to 20 mm.

7. The hybrid electrode of claim 1 , wherein the collar member comprises an external diameter in a range of 12 mm to 22 mm and the pin comprises an external diameter in a range of 2 mm to 10 mm.

8. The hybrid electrode of claim 1 , wherein the collar member comprises a length in a range of 0.1 mm to 10 mm.

9. The hybrid electrode of claim 1 , wherein the pin is offset from the collar member contact surface in a range of 0.1 mm to 5 mm along the longitudinal axis.

10. The hybrid electrode of claim 1 , wherein the pin is offset from the collar member contact surface in a range of 0.5 mm to 1 mm along the longitudinal axis.

11. A resistance spot rivet welding apparatus comprising the hybrid electrode of claim 1 .

12. A method of resistance spot welding, the method comprising:
contacting a metallic rivet and an assembly comprising at least two parts and a metallic rivet with the hybrid electrode of claim 1 and a second electrode, wherein the metallic rivet and the assembly are interposed between the hybrid electrode and the second electrode; and
passing a weld current between the hybrid electrode and the second electrode, through the assembly and the metallic rivet, thereby forming a weld securing together the at least two parts of the assembly.

13. The method of claim 12 , wherein a first part of the least two parts of the assembly comprises a first material and a second part of the least two parts comprises a second material, and wherein the first material differs from the second material.

14. The method of claim 13 , wherein the first material comprises at least one of aluminum and an aluminum alloy and the second material comprises at least one of iron and an iron alloy.

15. The method of claim 12 , wherein during the passing a weld current between the hybrid electrode and the second electrode, through the assembly and the metallic rivet, the collar member engages the assembly to limit a penetration depth of the hybrid electrode into the assembly.

16. The method of claim 12 , wherein during the passing a weld current between the hybrid electrode and the second electrode, through the assembly and the metallic rivet, the metallic rivet is intermediate the second electrode and the assembly.

17. The hybrid electrode of claim 1 , wherein the pin contact surface is substantially parallel to the collar member contact surface.

Assignees

• Howmet Aerospace Inc

Inventors

• Spinella Donald J
• Fedusa Anthony J

Classifications

• B21J15/02

  Riveting procedures · CPC title

• B21J15/36

  Rivet sets, i.e. tools for forming heads; Mandrels for expanding parts of hollow rivets · CPC title

• B23K35/222

  Non-consumable electrodes · CPC title

• B21J15/08

  Riveting by applying heat {, e.g.} to the end parts of the rivets to enable heads to be formed {(B21J15/027 takes precedence)} · CPC title

• B23K35/0205

  Non-consumable electrodes; C-electrodes · CPC title