Method for metallurgically joining a tube to a member

A method for metallurgically joining a first tube to a member comprising the steps of:

• a) obtaining a first tube having a flange;
• b) obtaining a member;
• c) obtaining a welding/brazing first electrode wheel having a first axis of rotation and having a first rim;
• d) disposing the first tube and the member with the flange contacting the member directly and/or indirectly through an intervening welding/brazing joining material;
• e) disposing the first rim of the first electrode wheel in direct contact with the flange;
• f) after steps a) through e), creating a resistance welding/brazing current path through the flange and the member using at least the first electrode wheel creating a seam weld/braze zone which includes at least some of the flange and at least some of the member;
• and
• g) during step f), rotating the first electrode wheel about the first axis of rotation, wherein the flange is an annular outwardly-extending end flange disposed proximate an end of the first tube, wherein the first tube includes a centerline axis at the flange, and wherein the first axis of rotation is substantially perpendicular to the centerline axis during step f), and wherein the member is a second tube having an annular outwardly-extending end flange, wherein step d) disposes the first tube and the second tube with the flange of the first tube contacting the end flange of the second tube either directly or indirectly through an intervening welding/brazing joining material.

A method for metallurgically joining a first tube to a member comprising the steps of:

• a) obtaining a first tube having a flange;
• b) obtaining a member;
• c) obtaining a welding/brazing first electrode wheel having a first axis of rotation and having a first rim;
• d) disposing the first tube and the member with the flange contacting the member directly and/or indirectly through an intervening welding/brazing joining material;
• e) disposing the first rim of the first electrode wheel in direct contact with the flange;
• f) after steps a) through e), creating a resistance welding/brazing current oath through the flange and the member using at least the first electrode wheel creating a seam weld/braze zone which includes at least some of the flange and at least some of the member;
• and
• g) during step f), rotating the first electrode wheel about the first axis of rotation, wherein the flange is an annular outwardly-extending end flange disposed proximate an end of the first tube, wherein the first tube includes a centerline axis at the flange, wherein the first axis of rotation is substantially perpendicular to the centerline axis during step f), and wherein the member is a non-tubular member having opposing first and second surfaces, wherein step d) disposes the first tube and the member with the flange of the first tube contacting the first surface of the member directly and/or indirectly through an intervening welding/brazing joining material, and also including the steps of obtaining a second electrode wheel having a second axis of rotation and having a second rim and disposing the second rim of the second electrode wheel in direct contact with the second surface of the member, wherein step f) also uses the second electrode wheel in creating the resistance welding/brazing current path, and additionally including during step f the step of counter-rotating the second electrode wheel at substantially the same rim speed as that of the first electrode wheel.

A method for metallurgically joining a first tube to a member comprising the steps of:

• a) obtaining a first tube having a flange;
• b) obtaining a member;
• c) obtaining a first electrode wheel having a first axis of rotation and having a first rim;
• d) disposing the first tube and the member with the flange contacting the member directly and/or indirectly through an intervening welding joining material;
• e) disposing the first rim of the first electrode wheel in direct contact with the flange;
• f) after steps a) through e), creating a resistance welding current path through the flange and the member using at least the first electrode wheel creating a seam weld zone which includes at least some of the flange and at least some of the member;
• and
• g) during step f), rotating the first electrode wheel about the first axis of rotation.

A method for metallurgically joining a first tube to a member comprising the steps of:

• a) obtaining a first tube having a flange;
• b) obtaining a member;
• c) obtaining a first electrode wheel having a first axis of rotation and having a first rim;
• d) disposing the first tube and the member with the flange contacting the member indirectly through an intervening brazing joining material;
• e) disposing the first rim of the first electrode wheel in direct contact with the flange;
• f) after steps a) through e), creating a resistance brazing current path through the flange and the member using at least the first electrode wheel creating a seam braze zone which includes at least some of the flange and at least some of the member;
• and
• g) during step f), rotating the first electrode wheel about the first axis of rotation.