Resistance welding of zinc-coated steel

Claim 1

A method for forming a hermetic weld between zinc-coated steel members, at least one of said members having a metallic copper layer between the zinc coating and the steel, said method comprising temporarily heating faying surfaces of the members to fuse the steel, said heating being generated by an electrical current passing between the members at the faying surfaces and applied by electrodes in contact with a surface of each member remote from the faying surface, said copper layer extending at the faying surface and the electrode contact surface of said one member, said copper layer at the faying surface being sufficient to melt during heating, flow into fissures formed in the fused steel and thereafter solidify to hermetically seal the weld, said copper layer at said electrode contact surface being sufficient to protect the underlying steel against corrosion despite zinc vaporization from said surface during welding.

Claim 2

A method for forming a hermetic weld between zinc-coated steel members, at least one of said members having a metallic copper layer between the zinc coating and the steel, said method comprising temporarily heating faying surfaces of the members to fuse the steel, said heating being generated by an electrical current passing between the members at the faying surfaces and applied by electrodes in contact with a surface of each member remote from the faying surface, said copper layer extending at the faying surface and the electrode contact surface of said one member, said copper layer at the faying surface being sufficient to melt during heating, flow into fissures formed in the fused steel and thereafter solidify to hermetically seal the weld, said copper layer at said electrode contact surface being sufficient to protect the underlying steel against corrosion despite zinc vaporization from said surface during welding.

Claim 3

A method for forming a hermetic weld between thin zinc-coated steel members, each member comprising a faying surface for the intended weld and a surface opposite the faying surfaces, at least one of said members having a metallic copper layer intermediate the zinc coating and the steel at the faying and opposite surfaces, said method comprising juxtaposing the faying surfaces, contacting the opposite surfaces with electrodes, pressing the electrodes together to press the faying surfaces into intimate contact, applying a short duration, high amperage alternating electrical current between the electrodes to temporarily resistively heat the faying surfaces to a temperature sufficient to fuse steel and form the weld, said heating vaporizing zinc from the faying surfaces and melting the copper layer, which copper melt is extruded by the electrode pressure to expose the steel for fusion bonding, said copper melt flowing into fissures within the fused steel and after said current solidifying to seal the weld, said electrical current also heating the opposite electrode-contact surface of said member having the copper layer to vaporize zinc from said surface, whereupon the copper layer is exposed and protects the underlying steel against subsequent corrosion.

Claim 4

A method for forming a hermetic weld between thin zinc-coated steel members, each member comprising a faying surface for the intended weld and a surface opposite the faying surfaces, at least one of said members having a metallic copper layer intermediate the zinc coating and the steel at the faying and opposite surfaces, said method comprising juxtaposing the faying surfaces, contacting the opposite surfaces with electrodes, pressing the electrodes together to press the faying surfaces into intimate contact, applying a short duration, high amperage alternating electrical current between the electrodes to temporarily resistively heat the faying surfaces to a temperature sufficient to fuse steel and form the weld, said heating vaporizing zinc from the faying surfaces and melting the copper layer, which copper melt is extruded by the electrode pressure to expose the steel for fusion bonding, said copper melt flowing into fissures within the fused steel and after said current solidifying to seal the weld, said electrical current also heating the opposite electrode-contact surface of said member having the copper layer to vaporize zinc from said surface, whereupon the copper layer is exposed and protects the underlying steel against subsequent corrosion.