Abstract A process is provided for welding metal bodies together, at least one of the metal bodies comprising a metallic material that is at least 50% glassy. The process comprises (a) clamping overlapped portions of the bodies between electrodes and applying a clamping force to the overlapped portions; (b) passing an electrical current having a rapid decay such that at least about 90% of the energy is delivered in less than about 4 x 10-3 sec through the bodies to melt at least a portion of one of the bodies, and (c) extracting heat from the bodies through the electrodes at a rate of at least about 105 DEG C/sec by employing high conductivity electrodes having a thermal conductivity of at least about 0.30 cal/sec/cm2/ DEG C to form a weld nugget joining the bodies. The weld nugget so formed has a shear strength which is at least 25% of the tensile strength of the body having the lowest tensile strength.
A process for welding at least two metal bodies together, at least one of which comprises a metallic material that is at least 50% glassy, comprising (a) clamping overlapped portions of the bodies between electrodes and applying a clamping force to the overlapped portions; (b) passing an electrical current having a rapid decay such that at least 90% of the energy is delivered in less than 4 × 10 -3 sec through the bodies sufficient to melt at least a portion of one of the bodies; and (c) extracting heat from the bodies through the electrodes to cool the bodies at a rate of at least 10 5 ° C./sec by employing high conductivity electrodes having a thermal conductivity of at least about 0.30 cal/sec/cm 2 /° C. to form a weld nugget having a high shear strength which is at least 25% of the tensile strength of the body having the lowest tensile strength.
Claim 2
Dependent Claim
155 words
A process for welding at least two metal bodies together, at least one of which comprises a metallic material that is at least 50% glassy, comprising (a) clamping overlapped portions of the bodies between electrodes and applying a clamping force to the overlapped portions; (b) passing an electrical current having a rapid decay such that at least 90% of the energy is delivered in less than 4 × 10 -3 sec through the bodies sufficient to melt at least a portion of one of the bodies; and (c) extracting heat from the bodies through the electrodes to cool the bodies at a rate of at least 10 5 ° C./sec by employing high conductivity electrodes having a thermal conductivity of at least about 0.30 cal/sec/cm 2 /° C. to form a weld nugget having a high shear strength which is at least 25% of the tensile strength of the body having the lowest tensile strength.
Claim 3
Dependent Claim
18 words
The process of claim 1 in which at least one of the bodies welded together is substantially glassy.
Claim 4
Dependent Claim
18 words
The process of claim 1 in which at least one of the bodies welded together is totally glassy.
Claim 5
Dependent Claim
22 words
The process of claim 1 in which the electrodes have a thermal conductivity of at least about 0.75 cal/sec/cm 2 /° C.
Claim 6
Dependent Claim
33 words
The process of claim 4 in which the electrodes are selected from the group consisting of copper, copper plus 0.95 wt % chromium and pyrolytic graphite with c-axis normal to the welding plane.
Claim 7
Dependent Claim
24 words
The process of claim 1 in which two bodies are welded together, both of which comprise metallic materials that are at least 50% glassy.