Hybrid workpiece joining

Abstract

A joining device includes a nose, a punch, and a die anvil. The punch is coaxially slidable within the nose. A fastener is arranged within the nose and is coaxially slidable within the nose and movable by the punch. An ultrasonic vibration is focused through the die anvil to a zone on a material assembly arranged thereon for heating the zone. The punch is configured to drive the fastener outwardly from the nose and into the material assembly at the zone.

1 . A joining device comprising:
 a nose;   a punch coaxially slidable within the nose;   a fastener arranged within the nose, the fastener being coaxially slidable within the nose and movable by the punch; and   a die anvil, wherein an ultrasonic vibration is focused through the die anvil to a zone on a material assembly arranged thereon for heating the zone, and wherein the punch is configured to drive the fastener outwardly from the nose and into the material assembly at the zone.   
     
     
         2 . The joining device of  claim 1 , wherein the material assembly includes a first and second workpiece and wherein the fastener is configured to join the first workpiece to the second workpiece. 
     
     
         3 . The joining device of  claim 2 , wherein the fastener further includes a head and a shank extending from the head, and wherein the punch contacts the fastener at the head and drives the shank through the first workpiece and into the second workpiece. 
     
     
         4 . The joining device of  claim 3 , wherein the die anvil has a die face that receives the second workpiece when the shank of the fastener is in the zone, and wherein the shank of the fastener is deformed to create a mechanical joint with the first and second workpieces. 
     
     
         5 . The joining device of  claim 1 , wherein at least a portion of the zone on the material assembly is fused upon cooling of the zone. 
     
     
         6 . A joining device comprising:
 a nose horn;   a punch coaxially slidable within the nose horn;   a fastener arranged within the nose horn, the fastener being coaxially slidable within the nose horn and movable by the punch; and   a die having a material assembly arranged thereon, wherein the nose horn is axially movable to a position contacting the material assembly, wherein an ultrasonic vibration is focused through the nose horn to a zone on the material assembly for heating the zone, and wherein the punch is configured to drive the fastener outwardly from the nose horn and into the material assembly at the zone.   
     
     
         7 . The joining device of  claim 6 , wherein the material assembly includes a first and second workpiece and wherein the fastener is configured to join the first workpiece to the second workpiece. 
     
     
         8 . The joining device of  claim 7 , wherein the fastener further includes a head and a shank extending from the head, and wherein the punch contacts the fastener at the head and drives the shank through the first workpiece and into the second workpiece. 
     
     
         9 . The joining device of  claim 8 , wherein the die has a die face that receives the second workpiece when the shank of the fastener is in the zone, and wherein the shank of the fastener is deformed to create a mechanical joint with the first and second workpieces. 
     
     
         10 . The joining device of  claim 6 , wherein at least a portion of the zone on the material assembly is fused upon cooling of the zone. 
     
     
         11 . A joining device comprising:
 a nose;   a punch coaxially slidable within the nose;   a fastener arranged within the nose, the fastener being coaxially slidable within the nose and movable by the punch; and   an electrode die, wherein an electrical current is focused through the electrode die to a zone on a material assembly arranged thereon for heating the zone, and wherein the punch is configured to drive the fastener outwardly from the nose and into the material assembly at the zone.   
     
     
         12 . The joining device of  claim 11 , wherein the electrode die further comprises:
 an insulator;   a first conductor arranged about the insulator; and   a second conductor arranged on an end surface of the first conductor, the second conductor configured to contact the material assembly.   
     
     
         13 . The joining device of  claim 12 , wherein the insulator is one of a ceramic and a polymer. 
     
     
         14 . The joining device of  claim 12 , wherein the first conductor is a tungsten carbide. 
     
     
         15 . The joining device of  claim 12 , wherein the second conductor is a steel. 
     
     
         16 . The joining device of  claim 11 , wherein the material assembly includes a first and second workpiece and wherein the fastener is configured to join the first workpiece to the second workpiece. 
     
     
         17 . The joining device of  claim 16 , wherein the fastener further includes a head and a shank extending from the head, and wherein the punch contacts the fastener at the head and drives the shank through the first workpiece and into the second workpiece. 
     
     
         18 . The joining device of  claim 17 , wherein at least a portion of the zone on the material assembly is fused upon cooling of the zone. 
     
     
         19 . The joining device of  claim 17 , wherein the shank of the fastener is deformed to create a mechanical joint with the first and second workpieces. 
     
     
         20 . The joining device of  claim 16 , wherein an electrical power source is interconnected with the electrode die to selectively create an electrical circuit for conducting electrical current through the first and second conductors, wherein the electrical current at the second conductor locally heats the second workpiece.