Capacitor discharge weld for connecting tubular twist beam profiles to cast trailing arm via adapter ring
A suspension component for a vehicle includes a cast iron body, a high strength steel tube and an adapter ring. The adapter ring includes a protrusion engaged with a face of the cast iron body. The protrusion is heated to a plasticized state as a capacitor is discharged through the protrusion and the face. The adapter ring is welded to the body upon cooling of the adapter ring. The high strength steel tube is fixed to the adapter ring.
1. A suspension component for a vehicle, comprising:
a suspension arm comprising a cast iron body having a tubular boss terminating at an axially facing end face;
an adapter ring comprising an annular body having an axially extending through aperture and an axially facing end surface having an axially extending annular protrusion concentrically disposed on said end surface, said protrusion being deformably heated to a plasticized state and welded to the end face of said tubular boss through a capacitor discharge welding process;
said adapter ring further comprising an opposing axially facing end surface defining an annular radially extending flange, and having an annular pilot extending in an axial direction from said flange opposite said protrusion, a surface of said flange facing an axial direction opposite said protrusion defining a land radially outward of said pilot; and
a steel tube terminating at an axially facing end face, wherein said pilot is axially inserted within said steel tube and the end face of said steel tube is fixed to said land of said adapter ring;
wherein said aperture in said adapter ring allows an electrode to pass through said steel tube and said adapter ring to engage said cast iron body, and
wherein said protrusion on said adapter ring is heated to a plasticized state as a capacitor is discharged through said protrusion and the end face of said tubular boss.
2. The suspension component of claim 1 wherein said tubular boss and said adapter ring have substantially similarly sized outer diameters.
3. The suspension component of claim 1 wherein said steel tube is constructed from a micro alloyed steel including one of ferrite, bainite and martensite.
4. The suspension component of claim 1 wherein said steel tube is constructed from 22MnB5.
5. The suspension component of claim 1 wherein said adapter ring is constructed from steel having a maximum carbon content of 0.28 percent.