Method and apparatus for component alignment and elimination of tacking in a welding process
An improved apparatus and method of joining two metallic components prior to making a full seam weld is disclosed. A first inner structural metallic component has at least one neutral zone, an inner surface, an outer surface and an aperture located in the neutral zone. A second outer structural metallic component has at least one neutral zone, an inner surface, an outer surface and a dimple with a raised portion on the inner surface and a recessed portion on the outer surface. The method uses the steps of joining the first and second metallic components so that the first component outer surface and the second component inner surface are directly adjacent each other, and joining the two structural metallic components by forming a full seam weld between the two components.
1 . A method of joining two metallic components prior to making a full seam weld comprising:
providing a first inner structural metallic component comprising at least one neutral zone, wherein said first component has an inner surface and an outer surface and an aperture in said neutral zone extending from said inner surface to said outer surface;
providing a second outer structural metallic component comprising at least one neutral zone, wherein said second component has an inner surface and an outer surface, wherein said neutral zone has a dimple comprising a raised portion on said second component inner surface and a recessed portion on said second component outer surface;
joining said first and said second metallic components so that said first component outer surface and said second component inner surface are directly adjacent each other, said first component neutral zone is 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.
2 . The method defined in claim 1 , wherein said first and said second structural components each have at least two neutral zones and cooperating apertures and dimples.
3 . The method defined in claim 1 , further comprising interlocking said first and said second structural components.
4 . The method defined in claim 1 , wherein said aperture has a constant diameter.
5 . The method defined in claim 1 , wherein said dimple extends through said aperture of said first structural component inner surface.
6 . The method defined in claim 1 , wherein said dimple is formed by embossing.
7 . The method defined in claim 1 , wherein said first structural component and said second structural component are structural automotive metallic components comprising at least a pair of either side rails, cross members, or brackets.
8 . The method defined in claim 1 , wherein said raised dimple portion on said second structural component inner surface has a diameter and said recessed dimple portion on said second structural component outer surface has a diameter, wherein said diameter of said raised dimple portion is larger than said diameter of said recessed dimple portion.
9 . The method defined in claim 8 , wherein said aperture diameter is larger than said raised dimple portion diameter.
10 . 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.
11 . 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.
12 . An automotive vehicle frame sub-assembly according to claim 11 , wherein said first flange portion and said second flange portion of said first structural metallic component are parallel to each other and perpendicular to said intermediate portion.
13 . An automotive vehicle frame sub-assembly according to claim 11 , wherein said first flange portion and said second flange portion of said second structural metallic component are parallel to each other and perpendicular to said intermediate portion and said first flange portion
14 . An automotive vehicle frame sub-assembly according to claim 11 , wherein said dimple comprises a raised portion on said flange portions inner surfaces and a recessed portion on said flange portions outer surfaces of said second structural metallic component.