Capacitive discharge welding of dissimilar metals

A method of joining a first piece of an automotive component to a second piece of the automotive component, one of the first and second pieces made from steel and the other of the first and second pieces made from one of ductile iron and titanium, the method comprising:

• machining a fay surface onto each of the first and second pieces of the automotive component;
• cleaning the fay surfaces of each of the first and second pieces of the automotive component;
• forming a metal filler from a sheet of an alloy having greater than 20% nickel;
• placing the metal filler between the fay surfaces of the first and second pieces of the automotive component;
• holding the first and second pieces together with the metal filler positioned between the fay surfaces of the first and second pieces;
• and
• passing an electric current through the first piece, the metal filler and the second piece to melt the metal filler and weld the first piece to the second piece.

A method of joining a first piece of an automotive component to a second piece of the automotive component, one of the first and second pieces made from steel and the other of the first and second pieces made from aluminum, the method comprising:

• machining a fay surface onto each of the first and second pieces of the automotive component;
• cleaning the fay surfaces of each of the first and second pieces of the automotive component;
• forming a metal filler from a sheet of one of an alloy having greater than 50% nickel and a copper alloy;
• placing the metal filler between the fay surfaces of the first and second pieces of the automotive component;
• holding the first and second pieces together with the metal filler positioned between the fay surfaces of the first and second pieces;
• and
• passing an electric current through the first piece, the metal filler and the second piece to melt the metal filler and weld the first piece to the second piece.