Method of capacitive discharge welding firing tip to spark plug electrode

1. A method of attaching a firing tip to a spark plug electrode, comprising the steps of:

aligning the firing tip with the spark plug electrode;

pressing the firing tip against the spark plug electrode; and

capacitive discharge welding the firing tip to the spark plug electrode by releasing stored energy from one or more energy storage devices so that weld current rapidly flows through the firing tip and the spark plug electrode, wherein the firing tip is made from a precious metal material and the spark plug electrode is made from a nickel-based material and the capacitive discharge welding forms a heat affected zone with a capacitive discharge weld joint between the firing tip and the spark plug electrode.

2. The method of claim 1 , wherein the firing tip is made from a precious metal material that includes at least one of the following elements: iridium (Ir), platinum (Pt), rhodium (Rh), ruthenium (Ru), palladium (Pd), gold (Au), silver (Ag) or tungsten (W).

3. The method of claim 1 , wherein the aligning step further comprises maintaining the firing tip in a pocket of a vacuum-driven welding arbor while the welding arbor aligns the firing tip with an inner surface of a spark plug ground electrode.

4. The method of claim 1 , wherein the aligning step further comprises maintaining the firing tip in a pocket of a vacuum-driven welding arbor while the welding arbor aligns the firing tip with a distal end surface of a spark plug center electrode.

5. The method of claim 1 , wherein the pressing step further comprises pressing a spherical-shaped firing tip against a nickel-based spark plug electrode with an initial weld force of less than 15 lbs.

6. The method of claim 1 , wherein the capacitive discharge welding step further comprises rapidly releasing stored energy from one or more energy storage devices, achieving a peak weld power soon after the stored energy is released, rapidly decreasing the weld power after the peak weld power is achieved, and ceasing the weld power after the weld power is rapidly decreased so that the total weld time less than about 40 ms.

7. The method of claim 1 , wherein the capacitive discharge welding step further comprises rapidly releasing stored energy from one or more energy storage devices, achieving a maximum interface temperature at an interface between the firing tip and spark plug electrode soon after the stored energy is released, and rapidly cooling the interface temperature after the maximum interface temperature is achieved so that a maximum interface temperature of over 2000° C. is achieved.

8. The method of claim 1 , wherein the capacitive discharge welding step further comprises forming a heat affected zone with a volume that is smaller than that formed during a comparable resistance welding event.

9. A method of attaching a firing tip to a spark plug electrode, comprising the steps of:

aligning the firing tip with the spark plug electrode;

pressing the firing tip against the spark plug electrode; and

capacitive discharge welding the firing tip to the spark plug electrode by releasing stored energy from one or more energy storage devices so that weld current rapidly flows through the firing tip and the spark plug electrode, wherein the capacitive discharge welding step forms a heat affected zone with a permanent capacitive discharge weld joint between the firing tip and the spark plug electrode, and the distance that the firing tip is sunk into the spark plug electrode during capacitive discharge welding is limited to 0.25 mm or less.

10. The method of claim 1 , wherein the capacitive discharge welding step further comprises maintaining the shape of a spherical firing tip during capacitive discharge welding so that its spherical shape is largely intact after the welding process.

11. The method of claim 1 , wherein the capacitive discharge welding step further comprises forming a heat affected zone that is largely devoid of intermetallic compounds or trapped gases at the capacitive discharge weld joint.

12. The method of claim 1 , wherein the capacitive discharge welding step further comprises rapidly applying weld current to a junction between the firing tip and the spark plug electrode so that a pool of molten firing tip and electrode material is formed, and rapidly cooling the junction between the firing tip and the spark plug electrode so that the pool of molten firing tip and electrode material quickly solidifies into a heat affected zone with a relatively fine microstructure.

13. The method of claim 1 , further comprising the step of:

carrying out one or more post-capacitive discharge welding processes after the firing tip has been capacitive discharge welded to the spark plug electrode, wherein the post-capacitive discharge welding processes include planishing and resistance welding the firing tip so that it is flattened against the spark plug electrode.

14. The method of claim 13 , wherein the volume of the heat affected zone of the planished and resistance welded firing tip is smaller than that formed during a comparable resistance welding and planishing method.

15. A spark plug electrode, comprising:

an electrode body; and

a firing tip attached to the electrode body through a heat affected zone with a capacitive discharge weld joint, wherein the firing tip is made from a precious metal material and the electrode body is made from a nickel-based material, the capacitive discharge weld joint includes solidified molten material from both the electrode body and the firing tip, and at least part of the heat affected zone includes a relatively fine microstructure.