Ultrasonic Resistance Welding Process And Apparatus

An ultrasonic resistance welding apparatus 10 contains a resistance spot welding apparatus 15, a first electrode 16 and a vibrable second electrode 18, the vibrable second electrode 18 in operable communication with an ultrasonic transducer 12, whereby the ultrasonic transducer 12 selectively imparts vibratory energy to the vibrable second electrode 18 based on signals from a controller 32. The vibrable second electrode 18 may be tuned or designed to resonate within 2.5% of an operating frequency of the ultrasonic transducer 12. During operation of the welding apparatus 10, a tip 19 of the second vibrable electrode 18 may be positioned at an anti-nodal point 38 of the vibratory energy and the vibrable second electrode 18 may be attached to the resistance spot welding apparatus 15 at a nodal plane 36 of the vibratory energy. A process for employing the apparatus 10 is also presented.