Resistance welding methods and apparatus
AssigneesSpirit AeroSystems, Inc., Stichting TPRC
InventorsKerrick Robert Dando, Andrea Christine Meyer, Ulrich Sachs, Thibault Hernandez
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Abstract
Disclosed is a method of resistance welding between composite articles. A conductive element is provided between faying surfaces, having a plurality of lower resistivity electrode portions spaced apart along the length of the contact area between the composite articles. The electrode portions can be used to spot weld across the electrode portions, and along a longitudinal portion of the conductive element between the electrode portions by application of an electrical current. Also disclosed are apparatus for use in the resistance welding methods and composite articles and structures and elements incorporating the conductive element.
Claims20
A method of resistance welding a first faying surface of a first composite article to a second faying surface of a second composite article, wherein one or both of the faying surfaces comprises a meltable or softenable material;
- the method comprising:
- contacting the first and second faying surfaces to define a contact area therebetween;
- providing a conductive element between the faying surfaces along a length of the contact area;
- the conductive element comprising a plurality of lower resistivity electrode portions spaced apart along the length of the contact area;
- wherein each electrode portion extends across a respective width of the contact area and each end thereof comprising an electrode extending from the contact area;
- applying an electrical current between the electrodes of a first said electrode portion to raise the temperature of the meltable or softenable material and weld together a portion of the faying surfaces between the electrodes of the first electrode portion;
- applying an electrical current between the electrodes of a second said electrode portion to raise the temperature of the meltable or softenable material and weld together a portion of the faying surfaces between the electrodes of the second electrode portion;
- and
- applying an electrical current between electrodes of the first and second electrode portions to raise the temperature of the meltable or softenable material and weld together a portion of the faying surfaces of the first and second electrode portions.
A composite structure comprising a first composite article and a second composite article, and a join having an area defined by respective faying surfaces of the first and second composite articles;
- wherein the join comprises a meltable or softenable material by which the composite articles are held together;
- and
- wherein the composite structure comprises a conductive element in the join between the faying surfaces or embedded within one of the said faying surfaces along the join;
- the conductive element comprising a longitudinal portion having a length corresponding substantially to the length of the join;
- and a plurality of lower resistivity electrode portions spaced apart along a length of the conductive element, each electrode portion extending across a respective width of the conductive element and comprising an electrode at the ends thereof, wherein the electrodes extend beyond the respective widths of the join.
An electrical connection apparatus for use in resistance welding to form a closed-geometry composite structure defining a high-aspect ratio substantially enclosed volume;
- the apparatus comprising:
- a probe arrangement comprising:
- a foot portion having an engagement surface for engaging a surface of the substantially enclosed volume;
- and comprising an electrical contact element;
- a shoulder portion having an engaging surface for engaging an opposite surface of the substantially enclosed volume;
- a reconfigurable body portion operatively coupled between the foot portion and the shoulder portion;
- the reconfigurable body portion being remotely configurable between a contracted configuration, and an expanded configuration;
- wherein;
- in the contracted position the engagement surfaces are spaced apart by less than a distance between opposed surfaces of a substantially enclosed volume defined between composite articles;
- and in the expanded configuration the engagement surfaces are further spaced apart sufficient to engage opposed surfaces of the substantially enclosed volume and to urge the electrical contact element into electrical contact with an inner electrode within the substantially enclosed volume.
Dependencies are inferred from the claim text.