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Joining of light metal alloy workpieces to steel workpieces using resistance spot welding and adhesive

  • US 10,675,702 B2
  • Filed: 02/16/2017
  • Issued: 06/09/2020
  • Est. Priority Date: 02/16/2016
  • Status: Active Grant
First Claim
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1. A method of adhesive weld bonding an aluminum alloy workpiece and a steel workpiece together, the method comprising:

  • providing the aluminum alloy workpiece having a faying surface and the steel workpiece having a faying surface;

    applying a plurality of discrete adhesive ribbons to the faying surface of the aluminum alloy workpiece, the faying surface of steel workpiece, or the faying surfaces of both the aluminum alloy workpiece and the steel workpiece, the plurality of discrete adhesive ribbons comprising a curable polymer;

    assembling the aluminum alloy workpiece and the steel workpiece together in overlapping fashion such that the faying surface of the aluminum alloy workpiece and the faying surface of the steel workpiece establish a faying interface and, wherein, during such assembly, the discrete adhesive ribbons are spread out laterally between the faying surface of the aluminum alloy workpiece and the faying surface of the steel workpiece so that a plurality of adhesive free zones are established amongst one or more adhesive zones;

    forming a resistance spot weld that bonds the aluminum alloy workpiece and the steel workpiece together within one of the adhesive free zones, wherein forming the resistance spot weld comprises applying pressure to the aluminum alloy workpiece and the steel workpiece with a pair of opposed welding electrodes to bring the faying surface of the aluminum alloy workpiece and the faying surface of the steel workpiece together at the adhesive free zone and communicating an electrical current between the pair of welding electrodes and through the aluminum alloy workpiece and the steel workpiece at the adhesive free zone to melt the aluminum alloy workpiece and create a molten weld pool that wets the faying surface of the steel workpiece and, upon cessation of the electrical current, solidifies into a weld joint contained within the aluminum alloy workpiece that bonds to the faying surface of the steel workpiece.

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