Mechanical dimpling for vapor expression in welding
A method for welding together two workpieces. The method includes stamping, using a stamping system, a first workpiece comprising a material that creates vapor when melted, such as zinc. The first workpiece is stamped at a first preselected region to form a plurality of depressions in the first preselected region. The method further includes positioning the first preselected region adjacent a second preselected region of a second workpiece. After stamping and positioning as such, the method includes applying energy to at least one of the first preselected region and the second preselected region to melt material of the first and second workpieces to form a joint connecting together the first and second workpieces. Based on the configuration and arrangement created, any vapor formed by molten material vents from the joint being formed, between the depressions formed, and away from the first and second workpieces.
1. A method, for welding together a first workpiece and a second workpiece, comprising:
stamping, using a stamping system, a faying surface of the first workpiece at a plurality of preselected regions of the faying surface to form a plurality of depressions and protrusions in each of the plurality of preselected regions;
positioning at least one of the plurality of preselected regions adjacent a second preselected region of the second workpiece; and
applying energy to the at least one of the plurality of preselected regions and the second preselected region to melt material of the first and second workpieces to form a joint connecting the first workpiece to the second workpiece, wherein vapor formed by workpiece material being melted vents from the joint being formed, between the depressions and/or corresponding protrusions formed on the faying surface, and away from the first and second workpieces.
2. The method of claim 1 , wherein:
the stamping system comprises a plurality of teeth used in forming the depressions; and
each tooth has a tip being a first portion of the tooth contacting the faying surface of the first workpiece being stamped.
3. The method of claim 2 , wherein the tip of at least one of the teeth is elongated and the depression formed by the tooth comprises a corresponding elongated groove.
4. The method of claim 2 , wherein each of the protrusions has a polygon-based pyramid shape.
5. The method of claim 2 , wherein each of the protrusions has a triangle-based shape.
6. The method of claim 1 , wherein the stamping system comprises a steel punch having a punch face comprising a plurality of teeth forming the depressions.
7. The method of claim 1 , wherein stamping the first workpiece plastically deforms the first workpiece in the plurality of preselected regions to form the depressions.
8. The method of claim 1 , wherein:
a first preselected region in the plurality of preselected regions extends to or is adjacent a first edge of the first workpiece and a second preselected region in the plurality of preselected regions extends to or is adjacent a second edge of the second workpiece and first portions of the first workpiece do not overlap portions of the second workpiece; and
the joint formed is a lap joint.
9. The method of claim 1 , further comprising applying force to at least one of the first and second workpieces to bias the first and second workpieces toward each other during application of the energy to a first preselected region and a second preselected region in the plurality of preselected regions.
10. The method of claim 1 , wherein applying energy comprises applying a laser to the first and second workpieces.
11. The method of claim 1 , wherein at least one of the two workpieces comprises zinc, and the vapor is formed at least in part by the zinc when melting.
12. The method of claim 11 , wherein:
the depressions are first depressions;
the method further comprises stamping, using the stamping system, the second workpiece to form a plurality of second depressions; and
the vapor formed by zinc being melted is vented from the joint being formed, between the first depressions and the second depressions, and away from the first and second workpieces.
13. The method of claim 11 , wherein the first workpiece comprises steel coated with zinc.
14. The method of claim 11 , wherein the first workpiece comprises steel coated with a combination of zinc and aluminum.
15. The method of claim 11 , wherein the first workpiece and the second workpiece comprise steel coated with zinc.
16. The method of claim 11 , wherein the first workpiece and the second workpiece comprise steel coated with a combination of zinc and aluminum.
17. The method of claim 1 , further comprising promoting venting of the vapor from the joint being formed, comprising applying negative pressure to an environment of the first and second workpieces.
18. The method of claim 1 , further comprising promoting venting of the vapor from the joint being formed, comprising causing air to move in an environment of the first and second workpieces.
19. A method, for preparing a first workpiece for being welded to a second workpiece, comprising:
stamping, using a stamping system, a faying surface of the first workpiece at a plurality of preselected regions of the faying surface, to form a plurality of depressions and protrusions in the plurality of preselected regions;
wherein the stamping system comprises a plurality of teeth forming the depressions; and
wherein each tooth has a tip being a first portion of the tooth contacting the workpiece being stamped.
20. A method, for preparing a first workpiece for being welded to a second workpiece, comprising:
stamping, using a stamping system, a faying surface of the first workpiece at a plurality of preselected regions of the faying surface to form a plurality of depressions and protrusions in the plurality of preselected regions;
wherein the stamping system comprises a steel punch comprising a punch face including a plurality of teeth for forming the depressions.