Friction Spot Welding and Friction Seam Welding
First Claim
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1. A method of spot welding an upper material layer to a lower material layer relative to a welding axis, the upper material layer being positioned in overlying relation to at least a portion of the lower material layer, the upper and lower material layers having respective top and bottom surfaces, the method comprising:
- axially advancing and rotating a rod relative to the welding axis such that a distal end of the rod contacts the top surface of the upper material layer;
applying an axial force to the rotating rod such that frictional heat between the distal end of the rod and the upper material layer plasticizes a portion of the upper material layer;
with a portion of the upper material layer plasticized, applying the axial force to the rotating rod such that a portion of the bottom surface of the upper material layer and a portion of the top surface of the lower material layer are deformed, thereby forming a metallurgical bond between the upper and lower material layers; and
axially retracting the rod relative to the welding axis such that the distal end of the rod is removed from contact with the top surface of the upper material layer.
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Abstract
Systems and methods for spot welding and seam welding an upper material layer to a lower material layer using a rod. The rod can be a non-consumable rod or a consumable rod.
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Citations
38 Claims
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1. A method of spot welding an upper material layer to a lower material layer relative to a welding axis, the upper material layer being positioned in overlying relation to at least a portion of the lower material layer, the upper and lower material layers having respective top and bottom surfaces, the method comprising:
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axially advancing and rotating a rod relative to the welding axis such that a distal end of the rod contacts the top surface of the upper material layer; applying an axial force to the rotating rod such that frictional heat between the distal end of the rod and the upper material layer plasticizes a portion of the upper material layer; with a portion of the upper material layer plasticized, applying the axial force to the rotating rod such that a portion of the bottom surface of the upper material layer and a portion of the top surface of the lower material layer are deformed, thereby forming a metallurgical bond between the upper and lower material layers; and axially retracting the rod relative to the welding axis such that the distal end of the rod is removed from contact with the top surface of the upper material layer. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17)
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18. A method of lap seam welding an upper material layer to a lower material layer relative to a vertical axis, the upper material layer being secured in overlying relation to at least a portion of the lower material layer, the upper and lower material layers having respective top and bottom surfaces and being configured for movement along a weld traverse axis, the weld traverse axis being substantially perpendicular to the vertical axis, the method comprising:
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axially advancing and rotating a rod relative to the vertical axis such that a distal end of the rod contacts the top surface of the upper material layer; applying an axial force to the rotating rod such that frictional heat between the distal end of the rod and the upper material layer plasticizes a portion of the upper material layer; with a portion of the upper material layer plasticized, applying the axial force to the rotating rod such that a portion of the bottom surface of the upper material layer and a portion of the top surface of the lower material layer are deformed, axially advancing the upper and lower material layers relative to the weld traverse axis by a desired length, thereby forming a metallurgical bond of the desired length between the upper and lower material layers; and axially retracting the rod relative to the vertical axis such that the distal end of the rod is removed from contact with the top surface of the upper material layer. - View Dependent Claims (19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34)
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35. A method of lap seam welding an upper material layer to a lower material layer relative to a vertical axis, the upper material layer being secured in overlying relation to at least a portion of the lower material layer, the upper and lower material layers having respective top and bottom surfaces and being configured for movement along a weld traverse axis and a transverse axis, the weld traverse axis and the transverse axis being positioned in a plane substantially perpendicular to the vertical axis, the weld traverse axis being substantially perpendicular to the transverse axis, the method comprising:
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axially advancing and rotating a rod relative to the vertical axis such that a distal end of the rod contacts a first location on the top surface of the upper material layer; applying a first axial force to the rotating rod such that frictional heat between the distal end of the rod and the upper material layer plasticizes a portion of the upper material layer; with a portion of the upper material layer plasticized, applying the first axial force to the rotating rod such that a portion of the bottom surface of the upper material layer and a portion of the top surface of the lower material layer are deformed, axially advancing the upper and lower material layers relative to the weld traverse axis by a first desired length, thereby forming a first seam weld between the upper and lower material layers; axially retracting the rod relative to the vertical axis such that the distal end of the rod is removed from contact with the top surface of the upper material layer; axially advancing and rotating the rod relative to the vertical axis such that the distal end of the rod contacts a second location on the top surface of the upper material layer, the second location on the top surface being spaced from the first location relative to the transverse axis; applying a second axial force to the rotating rod such that frictional heat between the distal end of the rod and the upper material layer plasticizes a portion of the upper material layer; with a portion of the upper material layer plasticized, applying the second axial force to the rotating rod such that a portion of the bottom surface of the upper material layer and a portion of the top surface of the lower material layer are deformed, axially advancing the upper and lower material layers relative to the weld traverse axis by a second desired length, thereby forming a second seam weld between the upper and lower material layers; and axially retracting the rod relative to the vertical axis such that the distal end of the rod is removed from contact with the top surface of the upper material layer, wherein the first seam weld and the second seam weld overlap relative to the transverse axis. - View Dependent Claims (36, 37, 38)
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Specification