Patent ID: 7030333

Claim:
A method of joining plates comprising the steps of: providing first and second metal plates, the first plate including at least one hole; providing a stud made from an electrically conductive material, the stud including a head, a barrel and a weld tip, the barrel having opposite ends respectively connected to the head and the weld tip, the barrel having a diameter that is less than the diameter of the hole and having a length that is greater than the thickness of the first plate; locating the plates such the first plate is located between the stud and the second plate; locating the stud such that a central axis of the stud is aligned with a central axis of the hole; moving the stud toward the second plate such that the weld tip of the stud contacts the second plate and air gaps are respectively provided between the head and the first plate and between the barrel and the hole; applying an electric current through the stud, using the head of the stud and the second plate as electrodes, that is sufficient to melt the weld tip whereby the stud is bonded to the second plate at an end of the stud; and deforming the barrel of the stud to reduce the length of the barrel thereby reducing the air gap between the head of the stud and the first plate.