# US 10,870,166 B2 · UAM transition for fusion welding of dissimilar metal parts > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 10,870,166 B2 - Document ID: US10870166B2 - Status: Granted - Kind: B2 - Application number: 15/885,895 - Filed: 2018-02-01 - Published: 2019-08-01 - Granted: 2020-12-22 - Earliest claimed: 2018-02-01 - Assignees: Honda Motor Co., Ltd. - Applicants: Honda Motor Co., Ltd. - Inventors: Ryan M. Hahnlen - Web page: https://patentgrep.com/patent/US10870166B2 ## CPC - B23K 9/235: Preliminary treatment - B23K 20/10: making use of vibrations, e.g. ultrasonic welding - B23K 11/11: Spot welding - B23K 11/20: of different metals - B23K 11/34: Preliminary treatment - B23K 26/60: Preliminary treatment - B32B 15/012: {one layer being formed of an iron alloy or steel, another layer being formed of aluminium or an aluminium alloy} - B32B 15/18: comprising iron or steel {(B32B15/011, B32B15/012 and B32B15/013 take precedence)} - B32B 15/20: comprising aluminium or copper {(B32B15/016 and B32B15/017 take precedence)} - Y10T 428/12757: Fe - B23K: SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM - B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## Abstract Welded assemblies and related methods of making the welded assemblies include a first component of a first metal material, a second component of a second metal material that is different from the first metal material, and a transition material including one or more of a high entropy alloy, a pure element, and an alloy that is not a high entropy alloy, and that is arranged between and contacting the first component and the second component. An ultrasonic weld joins the transition material to the first component, and a fusion weld joins the first component to the second component. The fusion weld contact the first component, the second component, and the transition material. The amount or level of one or more of galvanic corrosion, intermetallic compounds, and solidification cracking in the fusion weld is less than if the first component was fusion welded directly to the second component. ## Claims ### Claim 1 A welded assembly comprising: a first component including a first metal material, a second component including a second metal material having a different composition than the first metal material, a transition material arranged between and contacting the first component and the second component, the transition material comprising one or more of a high entropy alloy, a pure element, and an alloy that is not a high entropy alloy, an ultrasonic weld joining the transition material to the first component, and a fusion weld extending through the ultrasonic weld and the transition material, and joining the first component to the second component; wherein the fusion weld contacts the first component, the second component, and the transition material; wherein the ultrasonic weld, the fusion weld, and the transition material are different portions of the welded assembly. ### Claim 2 (depends on 1) The welded assembly according to claim 1, wherein the fusion weld contacts the first component and the second component. ### Claim 3 (depends on 1) The welded assembly according to claim 1, wherein the fusion weld includes the first metal material, the second metal material, and the transition material. ### Claim 4 (depends on 1) The welded assembly according to claim 1, wherein: the transition material is a multi-layer structure including at least a first layer and a second layer; the first layer is arranged closest to the first component; the second layer is arranged closest to the second component; and the fusion weld contains less of one or more of galvanic corrosion, intermetallic compounds, and solidification cracking than if the second layer was arranged closest to the first component and the first layer was arranged closest to the second component. ### Claim 5 (depends on 4) The welded assembly according to claim 4, wherein at least one layer of the multi-layer structure includes vanadium or niobium. ### Claim 6 (depends on 4) The welded assembly according to claim 4, wherein layers of the multi-layer structure, including the first layer and the second layer, are themselves welded together at their interfaces other than by the fusion weld. ### Claim 7 (depends on 1) The welded assembly according to claim 1, wherein the fusion weld is a resistance spot weld. ### Claim 8 (depends on 1) The welded assembly according to claim 1, wherein the first metal material comprises aluminum, and the second metal material comprises steel. ### Claim 9 (depends on 1) The welded assembly according to claim 1, wherein the first component does not contact the second component. ### Claim 10 (depends on 1) The welded assembly according to claim 1, wherein the transition material is joined to the second component only by the fusion weld. ### Claim 11 A method of making a welded assembly, comprising: providing a transition material ultrasonically welded to a first component, arranging the transition material between the first component and a second component such that the transition material contacts the second component, and joining the first component to the second component by forming a fusion weld between the first component and the second component; wherein the first component comprises a first metal material, the second component comprises a second metal material having a different composition than the first metal material, and the transition material comprises one or more of a high entropy alloy, a pure element, and an alloy that is not a high entropy alloy, wherein the fusion weld contacts the first component, the second component, and the transition material. ### Claim 12 (depends on 11) The method according to claim 11, wherein the fusion weld passes through the transition material to contact the first component and the second component. ### Claim 13 (depends on 11) The method according to claim 11, wherein the fusion weld includes the first metal material, the second metal material, and the transition material. ### Claim 14 (depends on 11) The method according to claim 11, wherein: the transition material comprises a multi-layer structure including at least a first layer and a second layer; the first layer is arranged closest to the first component; the second layer is arranged closest to the second component; and the fusion weld contains less of one or more of galvanic corrosion, intermetallic compounds, and solidification cracking than if the second layer was arranged closest to the first component and the first layer was arranged closest to the second component. ### Claim 15 (depends on 14) The method according to claim 14, further comprising, before ultrasonic welding the transition material to the first component, welding layers of the multi-layer structure, including the first layer and the second layer, together at their interfaces. ### Claim 16 (depends on 11) The method according to claim 11, wherein providing includes ultrasonic welding the transition material to the first component. ### Claim 17 (depends on 11) The method according to claim 11, wherein the fusion weld is a resistance spot weld. ### Claim 18 (depends on 11) The method according to claim 11, wherein the first metal material comprises aluminum, and the second metal material comprises steel. ### Claim 19 (depends on 11) The method according to claim 11, wherein the first component does not contact the second component. ### Claim 20 (depends on 11) The method according to claim 11, wherein the transition material is joined to the second component only through the fusion weld.