This article describes the joint preparation, fit-up and design of various types of laser beam weld joints: butt joint, lap joint, flange joint, kissing weld, and wire joint. It explains the use of consumables for laser welding and highlights the special laser welding practices of steel, aluminum, and titanium engineering alloys. Laser weld quality and quality assessment are described with summaries of imperfections and how its operations contribute to providing repeatable and reliable laser welds. Relevant laser weld quality specifications are listed.

This article describes the process applications, advantages, and limitations of resistance seam welding. The fundamentals of lap seam welding are also reviewed. The article details the types of seam welds, namely, lap seam welds and mash seam welds, and the processing equipment used for lap seam welding. The primary factors used to determine the selection of electrodes, including alloy type and wheel configuration, are reviewed. The article also describes weld quality and process control procedures.

Resistance seam welding (RSEW) is a process in which the heat generated by resistance to the flow of electric current in the work metal is combined with pressure to produce a welded seam. This article discusses the various classes of the RSEW process, namely roll spot welding, reinforced roll spot welding, and leak-tight seam welding. It provides information on the applications of lap seam weld, mash seam weld, and butt seam weld. The article reviews the advantages and limitations of seam welding compared to resistance spot welding, projection welding, and laser welding. It describes the four basic types of resistance seam weld machines: circular, longitudinal, universal, and portable. The article concludes with a discussion on weld quality and process control for seam welding.

This article compares and contrasts mechanical joining techniques used in the manufacture of aluminum assemblies, including seaming, swaging, flanging, crimping, clinching, dimpling, interference and snap fits, and interlocking joints. It provides basic illustrations of the various methods and summarizes the advantages and disadvantages of each. The article also discusses the use of staples, nails, rivets, and threaded fasteners and provides relevant property and performance data.

The resistance welding processes commonly employed for joining aluminum are resistance spot welding, resistance seam welding, resistance roll welding, upset and flash welding for butt joining welding, and high-frequency resistance welding. This article discusses the general factors affecting resistance welding: electrical and thermal conductivities, rising temperature, plastic range, shrinkage, and surface oxide. It reviews the weldability of base materials such as Alclad alloys and aluminum metal-matrix composites. The article describes the joint design and welding procedures for resistance spot welding, as well as the joint type, equipment, and welding procedures for seam and roll spot welding. It concludes with information on flash welding, high-frequency welding, and cross-wire welding.

Laser-beam welding (LBW) is a joining process that produces coalescence of material with the heat obtained from the application of a concentrated coherent light beam impinging upon the surface to be welded. This article describes the steps that must be considered when selecting the LBW process. It reviews the individual process variables that influence procedure development of the LBW process. Joint design and special practices related to LBW are discussed. The article concludes with a discussion on the use of consumables and special welding practices.