CPC B23P 15/04 (2013.01) [F02C 7/00 (2013.01); F05D 2220/32 (2013.01); F05D 2230/232 (2013.01); F05D 2240/12 (2013.01); F05D 2240/30 (2013.01)] | 15 Claims |
1. A system comprising:
a dual wall structure, the dual wall structure including a core and a cover sheet, the cover sheet having a 3D contoured outer surface;
a resistance welder;
a cover sheet probe electrically coupled with the resistance welder, the cover sheet probe comprising a tip having a three dimensional (3D) contoured contacting area that follows the 3D contoured outer surface of the cover sheet of the dual wall structure;
an inner pedestal probe electrically coupled with the resistance welder, the inner pedestal probe to electrically couple with the dual wall structure; and
the resistance welder including a controller to control a supply of electric power to the cover sheet probe and control a pressing force of the tip of the cover sheet probe against the outer surface of the cover sheet, wherein the tip includes the 3D contoured contacting area to abut the 3D contoured outer surface of the cover sheet opposite an inner surface of the cover sheet, the inner surface abutting a pedestal included in the core, and the 3D contoured contacting area equal to or greater than a surface area of the pedestal contacting the inner surface of the cover sheet.
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