UAM-Interface Multimaterial Joint for Resistance Spot Welding
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Solution Overview
Problem
The automotive industry faces challenges in joining dissimilar metals using existing methods, such as adhesives and mechanical fasteners, which require additional resources, specialized equipment, and capital investment for infrastructure changes.
Innovation Solution
A multi-material component is created by joining a first component made of one material with a second component made of a different material using an ultrasonic additive manufacturing (UAM) interface and resistance spot welding (RSW), where the UAM interface can be excluded or included in the RSW joint, allowing for the use of existing assembly lines without re-tooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesives are used to join dissimilar metals, then joining capability is achieved, but specialized equipment, increased takt time, and separate thermal cycle are required
Solution Approach 1:
The patent replaces adhesive bonding (chemical/thermal process) with resistance spot welding (electromechanical process). The welding process uses electrical current and mechanical pressure to create direct metal-to-metal bonds, eliminating the need for adhesives, specialized curing equipment, and separate thermal cycles while achieving equivalent or superior joining strength
Solution Approach 2:
The patent makes existing resistance spot welding equipment multi-functional by enabling it to join dissimilar metals (aluminum and steel) through parameter optimization and electrode design, rather than requiring separate specialized equipment for different material types. This allows a single welding system to handle multiple material combinations
2Strength
If mechanical fasteners are used to join dissimilar metals, then joining capability is achieved, but added weight, cost, parts, and assembly time are required
Solution Approach 1:
The patent replaces mechanical fastening systems (screws, rivets, clips) with resistance spot welding, which creates direct metal bonds without requiring additional fastener parts. This eliminates the weight of fasteners, reduces part count, and decreases assembly time while maintaining or improving joint strength
Solution Approach 2:
The patent merges the joining function into the base components themselves by creating weld bonds between the aluminum component and steel component, rather than using separate fastener elements. This integration eliminates additional parts and reduces overall assembly weight
3Strength
If changing to a different joining process is implemented, then joining capability for dissimilar metals is improved, but new infrastructure, line re-design, and personnel training are required
Solution Approach 1:
The patent enables existing resistance spot welding equipment to join dissimilar metals (aluminum and steel) by optimizing welding parameters, electrode materials, and tooling designs. This makes the existing welding infrastructure multi-functional, capable of handling both similar and dissimilar metal joints without requiring new equipment or facilities
Solution Approach 2:
The patent achieves dissimilar metal joining by modifying welding parameters (current, voltage, time, pressure) and electrode characteristics rather than changing the fundamental joining process. This allows existing equipment to perform new functions through parameter optimization, avoiding infrastructure changes and extensive retraining
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method enables efficient joining of dissimilar metals like aluminum and steel without material degradation, reducing weight and assembly time, and allows for the use of existing welding equipment, thus eliminating the need for new infrastructure and personnel training.
Implementation Method 1
The insert is joined to the first component via an ultrasonic additive manufacturing (UAM) interface
Implementation Method 2
the second component is resistance spot welded (RSW) to the insert via a RSW joint
Implementation Method 3
Joining the second component to the insert can include resistance spot welding (RSW) the second component to the insert via a RSW joint
Data Source
AI summary
A vehicle body assembly is described herein, including a first structural component and a second structural component. The first structural component may be a roof component or a side panel, and include a first part including a first metal and a second part including a second metal different than the first metal. The second part is formed on a peripheral edge portion of the first part and defines a mounting flange for the first structural component. The second part is joined to the first part via an ultrasonic additive manufacturing (UAM) interface. The second structural component is including the second metal and is joined to the second part at the mounting flange via a resistance spot weld (RSW) joint.