Method of joining dissimilar materials

A method of joining a non-ferrous component to a ferrous component, said method comprising the steps of:

• pressing said non-ferrous component against one surface of said ferrous component at a predetermined joining location using a first electrode assembly to press against said non-ferrous component and a second electrode against another surface of said ferrous component;
• driving a self-piercing ferrous rivet through said non-ferrous component using said first electrode and at least into contact with a wall of said ferrous component at said joining location to mechanically attach said non-ferrous component to said ferrous component, the self-piercing ferrous rivet comprising a head attached to a hollow cylindrical shank with a tapered end so that the shank penetrates through said first component and into said second component and encloses material of said first component in the hollow of said shank;
• and
• passing an electrical current through said electrodes, said ferrous rivet, and said ferrous component at said joining location to fuse at least said ferrous rivet to said ferrous component;
• and
• stopping the flow of electrical current to form a welded bond between at least said rivet and said ferrous component.

A method of joining a sheet portion of a non-ferrous component to a ferrous tube having a first surface and a second surface opposing the first surface, said method comprising the steps of:

• pressing the sheet portion of the non-ferrous component against the first surface of the ferrous tube at a predetermined joining location using a first electrode assembly to press against said non-ferrous component and a second electrode against the second surface of the ferrous tube;
• driving a self-piercing ferrous rivet through the sheet portion of the non-ferrous component and at least into contact with the first surface of the ferrous tube at said joining location to mechanically attach said non-ferrous component to said ferrous tube, the self-piercing ferrous rivet comprising a head attached to a hollow cylindrical shank with a tapered end so that the shank penetrates through the sheet portion of the non-ferrous first component and into the ferrous tube and encloses material of the first component in the hollow of the shank;
• and
• passing an electrical current through the electrodes, the ferrous rivet, and the ferrous component at said joining location to fuse at least the ferrous rivet to the ferrous component;
• and
• stopping the flow of electrical current to form a welded bond between at least the rivet and the ferrous component.