Method and apparatus for component alignment and elimination of tacking in a welding process

A method of joining two structural metallic automotive components prior to making a full seam weld comprising:

• providing a first inner structural component comprising a first flange portion, an intermediate portion, and a second flange portion wherein said first flange, intermediate, and second flange portions have an inner surface and an outer surface, wherein said first flange portion and said second flange portion are parallel to each other and perpendicular to said intermediate portion and said first flange portion and said second flange portion have at least one neutral zone, and wherein each said neutral zone on each flange portion has an aperture extending from said inner surface to said outer surface;
• providing a second outer structural component comprising a first flange portion, an intermediate portion, and a second flange portion wherein said first flange, intermediate, and second flange portions have an inner surface and an outer surface, wherein said first flange portion and said second flange portion are parallel to each other and perpendicular to said intermediate portion and said first flange portion and said second flange portion have at least one neutral zone, and wherein each said neutral zone has a dimple comprising a raised portion on said flange portions inner surfaces and a recessed portion on said flange portions outer surfaces;
• joining said first inner and said second outer structural components so that said first inner component first flange portion outer surface is directly adjacent said second outer component first flange inner surface and said first component second flange portion outer surface is directly adjacent said second outer component first flange inner surface, wherein said first and second flange portions at said neutral zones are directly adjacent said second component neutral zone, and wherein said first component aperture is in axial alignment with said second component dimple and said dimple extends through said aperture;
• and
• forming a full seam weld between said first and said second components.

An automotive vehicle frame sub-assembly comprising, a first inner structural component comprising a first flange portion, an intermediate portion, and a second flange portion wherein said first flange portion, intermediate portion, and second flange portion have an inner surface and an outer surface, said first flange portion and said second flange portion have at least one neutral zone, and wherein said neutral zone on each flange portion has an aperture extending from said inner surface to said outer surface;

• a second outer structural component comprising a first flange portion, an intermediate portion, and a second flange portion wherein said first flange portion, intermediate portion, and second flange portion have an inner surface and an outer surface, and said second flange portion have at least one neutral zone, and wherein said neutral zone has a dimple;
• and
• wherein said first structural metallic component is connected to said second structural metallic component so that said first inner component first flange portion outer surface is directly adjacent said second outer component first flange inner surface and said first component second flange portion outer surface is directly adjacent said second outer component first flange inner surface, wherein said first and second flange portions' neutral zones are directly adjacent said second component neutral zone, and wherein said first component aperture is in axial alignment with said second component dimple and said dimple extends through said aperture.