US 11,984,691 B2
Resistance welding fastener, apparatus and methods
Donald J. Spinella, Greensburg, PA (US); and Daniel Bergstrom, Sarver, PA (US)
Assigned to Howmet Aerospace Inc., Pittsburgh, PA (US)
Filed by HOWMET AEROSPACE INC., Pittsburgh, PA (US)
Filed on Nov. 5, 2021, as Appl. No. 17/519,905.
Application 17/519,905 is a division of application No. 16/210,599, filed on Dec. 5, 2018, granted, now 11,196,185.
Application 16/210,599 is a continuation of application No. 14/611,555, filed on Feb. 2, 2015, granted, now 10,903,587, issued on Jan. 26, 2021.
Claims priority of provisional application 61/934,951, filed on Feb. 3, 2014.
Prior Publication US 2022/0059952 A1, Feb. 24, 2022
Int. Cl. H01R 4/02 (2006.01); B23K 11/11 (2006.01); B23K 11/20 (2006.01); B23K 35/02 (2006.01); B23K 103/20 (2006.01); F16B 5/08 (2006.01); F16B 37/06 (2006.01); H01R 4/62 (2006.01); H01R 43/02 (2006.01)
CPC H01R 4/027 (2013.01) [B23K 11/11 (2013.01); B23K 11/20 (2013.01); B23K 35/0288 (2013.01); F16B 37/061 (2013.01); H01R 43/0214 (2013.01); B23K 2103/20 (2018.08); F16B 5/08 (2013.01); H01R 4/625 (2013.01); Y10T 403/472 (2015.01)] 14 Claims
OG exemplary drawing
 
1. A method for fastening a first material to a second material using electrical resistance welding, comprising:
placing the first and second materials together in physical contact to form a stack;
placing a first electrically conductive fastener that is weldable to the second material in contact with the stack, the first fastener having
a cap,
a shaft extending from the cap and
an end distal to the cap,
the cap having an electrode receiving surface with a radiused portion;
placing the stack between a pair of electrodes, a first electrode of the pair of electrodes having a radiused portion;
placing the first electrode against the radiused portion of the electrode receiving surface;
placing a second electrode of the pair of electrodes in electrical continuity with the second material;
applying an electrical potential across the stack, inducing a current to flow through the first fastener and the stack and causing resistive heating;
moving the first fastener toward the second material; and
welding the first fastener to the second material, the first material being captured between the cap and the second material after the end is welded to the second material.