US 12,337,406 B2
Contoured electrodes for joining workpieces with curved surfaces
Michael J. Hayes, Fort Collins, CO (US); and Johnathan H. Mead, Columbus, OH (US)
Assigned to KTH Parts Industries, Inc., St. Paris, OH (US)
Filed by KTH Parts Industries, Inc., St. Paris, OH (US)
Filed on Apr. 4, 2022, as Appl. No. 17/713,184.
Prior Publication US 2023/0311237 A1, Oct. 5, 2023
Int. Cl. B23K 11/30 (2006.01)
CPC B23K 11/3081 (2013.01) 21 Claims
OG exemplary drawing
 
1. A method of electrical resistance spot welding, the method comprising the steps of:
(a) providing a first workpiece having a portion with a curvature of a first radius and a second workpiece having a first portion with a curvature matching the curvature of the first workpiece and a second portion having a curvature;
(b) providing first and second in-line electrodes that are each comprised of a body with a weld face at one end, the weld face having a contoured curvature, the contoured curvature of the first electrode covering the entire weld face of the first electrode and matching the curvature of the portion of the first workpiece, and the contoured curvature of the second electrode covering the entire weld face of the second electrode and matching the curvature of the second portion of the second workpiece, such that both electrodes and both workpieces are axially aligned in a first direction;
(c) contacting the first electrode weld face with the portion of the first workpiece such that the matching curvatures of the first electrode weld face and the portion of the first workpiece are both oriented in a same direction relative to one another and in contact;
(d) contacting the first portion of the second workpiece with the portion of the first workpiece such that the matching curvatures of the first workpiece and the first portion of the second workpiece are both oriented in a same direction relative to one another and in contact;
(e) contacting the second electrode weld face and the second portion of the second workpiece such that the matching curvatures of the second electrode weld face and the second portion of the second workpiece are both oriented in a same direction relative to one another and in contact; and
(f) applying pressure and electrical current to the first workpiece and the second workpiece to form at least one electrical resistance spot weld at the contacting portions of the first workpiece and the second workpiece.