Systems and methods to reduce air pocket formation during welding

A system, for joining a first workpiece and a second workpiece, comprising:

• a group of energy directors configured to be positioned at one of a first interface surface of the first workpiece and a second interface surface of the second workpiece, the group of energy directors comprising:
• a first energy director having a first height;
• a second energy director having a second height, being less than the first height, and positioned adjacent the first energy director;
• and
• a third energy director having the second height and positioned adjacent the first energy director,
• wherein the group of energy directors join together, by a substantially void-free weld in a weld area of the system, the first interface surface of the first workpiece and the second interface surface of the second workpiece during operation of the system, and
• wherein the group energy directors, in being configured to be positioned at one of the first interface surface and the second interface surface for joining the first interface surface and the second interface surface, are configured to, based on respective heights of the energy directors, melt the first energy director before melting the second director and the third energy director in response to application of input energy to form the substantially void-free weld within the weld area during operation of the system.

A system, for joining a first workpiece and a second workpiece, comprising:

• a first energy director having a first height;
• a second energy director having a second height, being less than the first height, and positioned adjacent the first energy director;
• and
• a third energy director having the second height and positioned adjacent the first energy director,
• wherein the first energy director, the second energy director, and the third energy director are configured to be positioned at one of a first interface surface and a second interface surface to join the first interface surface and the second interface surface and configured to melt sequentially, based on respective heights of the energy directors, the first energy director before melting the second director and the third energy director in response to application of energy to input form a substantially void-free weld within a weld area during operation of the system.