A conventional two-piece vehicle wheel includes an inner disc and an outer "full" rim. The disc can be cast, forged, or fabricated from steel, aluminum, or other alloys, and includes an inner annular wheel mounting portion and an outer annular portion. The wheel mounting portion defines an inboard mounting surface and includes a center pilot or hub hole and a plurality of lug receiving holes formed therethrough for mounting the wheel to an axle of the vehicle. The rim is fabricated from steel, aluminum, or other alloys, and includes an inboard tire bead seat retaining flange, an inboard tire bead seat, an axially extending well, an outboard tire bead seat, and an outboard tire bead seat retaining flange. In some instances, a three-piece wheel construction having a mounting cup secured to the disc is used. In both types of constructions, the outer annular portion of the disc is secured to the rim by a gas metal arc weld (GMAW) process, a vacuum electron beam welding (VEBW) process, a laser welding process, or a friction welding process.

A full face vehicle wheel is distinguished from other types of wheels by having a one-piece wheel disc construction. In particular, the full face wheel includes a "full face" disc and a "partial" rim. The full face disc can be formed cast, forged, or fabricated from steel, aluminium, magnesium or other alloys. The full face disc includes an inner annular wheel mounting portion and an outer annular portion which defines at least a portion of an outboard tire bead seat retaining flange of the wheel. The wheel mounting portion defines an inboard

mounting surface and includes a center pilot or hub hole and a plurality of lug receiving holes formed therethrough for mounting the wheel to an axle of the vehicle. The partial rim is fabricated from steel, aluminum, or other alloys, and includes an inboard tire bead seat retaining flange, an inboard tire bead seat, an axially extending well, and an outboard tire bead seat. In some instances, the outboard tire bead seat of the rim and the outer annular portion of the disc cooperate to form the outboard tire bead seat retaining flange of the full face wheel. In both types of constructions, the outboard tire bead seat of the rim is positioned adjacent the outer annular portion of the disc and is secured to the disc by a gas metal arc weld (GMAW) process, a vacuum electron beam welding (VEBW) process, a laser welding process, or a friction welding process.

SUMMARY OF THE INVENTION This invention relates to an improved vehicle wheel and method for producing the same, the vehicle wheel including a rim including at least an inboard portion, generally axially extending well, and an outboard portion, and a disc including at least an inner annular wheel mounting portion and an outer annular portion. The disc is joined to the rim by a non-vacuum electron beam welding process to produce a vehicle wheel including an inboard tire bead seat retaining flange, an inboard tire bead seat, a well, an outboard tire bead seat, and an outboard tire bead seat retaining flange. The method for producing the vehicle wheel includes the steps of: (a) providing a rim including at least an inboard portion, generally axially extending well, and an outboard portion; (b) providing a disc defining a disc axis and including at least an inner annular wheel mounting portion and an outer annular portion; (c) initially joining the rim and the disc together by a plurality of tack welds; and (d) joining the rim and the disc together by a non-vacuum electron beam welding process to produce the vehicle wheel, the vehicle wheel including an inboard tire bead seat retaining

flange, an inboard tire bead seat, a well, an outboard tire bead seat, and an outboard tire bead seat retaining flange, the non-vacuum electron beam welding process joining the rim and the disc together by a single continuous at least 3600 weld.

Other advantages of this invention will become apparent to those skilled in the art from the following detailed description of the preferred embodiments, when read in light of the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is a sectional view of a portion of a first embodiment of a vehicle wheel prior to joining the associated rim and disc together using a non-vacuum electron beam welding process in accordance with this invention..

Fig. 2 is an enlarged sectional view of a portion of the vehicle wheel illustrated in Fig. 1 showing the joining of the rim to the disc using the non- vacuum electron beam welding process of this invention.

Fig. 3 is a sectional view of a portion of a second embodiment of a vehicle wheel prior to joining the associated rim and disc together using a non- vacuum electron beam welding process in accordance with this invention.

Fig. 4 is an enlarged sectional view of a portion of the vehicle wheel illustrated in Fig. 3 showing the joining of the rim to the disc using the non- vacuum electron beam welding process of this invention.

Fig. 5 is a sectional view of a portion of a third embodiment of a vehicle wheel prior to joining the associated rim and disc together using a non-vacuum electron beam welding process in accordance with this invention.

Fig. 6 is an enlarged sectional view of a portion of the vehicle wheel illustrated in Fig. 5 showing the joining of the rim to the disc using the non- vacuum electron beam welding process of this invention.

Fig. 7 is a sectional view of a portion of a fourth embodiment of a vehicle wheel prior to joining the associated rim and disc together using a non-vacuum electron beam welding process in accordance with this invention.

Fig. 8 is an enlarged sectional view of a portion of the vehicle wheel illustrated in Fig. 7 showing the joining of the rim to the disc using the non- vacuum electron beam welding process of this invention.

Fig. 9 is a sectional view of a portion of a fifth embodiment of a vehicle wheel prior to joining the associated rim and disc together using a non-vacuum electron beam welding process in accordance with this invention.

Fig. 10 is an enlarged sectional view of a portion of the vehicle wheel illustrated in Fig. 9 showing the joining of the rim to the disc using the non- vacuum electron beam welding process of this invention.

Fig. 11 is a sectional view of a portion of a sixth embodiment of a vehicle wheel prior to joining the associated rim and disc together using a non-vacuum electron beam welding process in accordance with this invention.

Fig. 12 is an enlarged sectional view of a portion of the vehicle wheel illustrated in Fig. 11 showing the joining of the rim to the disc using the non- vacuum electron beam welding process of this invention.

Fig. 13 is a block diagram illustrating a sequence of steps for producing the associated vehicle wheels of this invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring now to the drawings, there is illustrated in Fig. 1 a sectional view of a portion of a first embodiment of an improved vehicle wheel, indicated generally at 10, in accordance with the present invention. The vehicle wheel 10 shown in this embodiment is a "modular" type of wheel, and includes a "partial" rim 12 and a "full face" wheel disc 14. Although this invention will be described in connection with the particular vehicle wheels illustrated herein, it will be

appreciated that the invention can be used in conjunction with other types of vehicle wheels.

The rim 12 is a fabricated rim preferably constructed of aluminum or other alloys thereof. Alternatively, the rim 12 can be formed from other metals, such as for example, steel. The rim 12 includes an inboard tire bead seat retaining flange 20, an inboard tire bead seat 22, a generally axially extending well 24, and an outboard end 25 which forms a portion of an outboard tire bead seat 26.

The disc 14 is preferably a cast disc constructed of aluminum or other alloys thereof. Alternatively, the disc 14 can be forged, fabricated, or otherwise formed, and/or can be formed from other metals, such as for example, magnesium and steel. Also, for manufacturing purposes, the rim 12 and the disc 14 are preferably formed from the same kind of metal; however, the rim 12 and the disc 14 may be formed from different metals if desired.

The disc 14 defines an axis X and includes a generally centrally located wheel mounting surface 30, an outer annular flange 32 which forms an outboard tire bead seat retaining flange 28 ofthe wheel 10, and an inboard portion 33 which forms a portion of the outboard tire bead seat 26. The wheel mounting flange 30 is provided with a centrally located pilot aperture 34, and a plurality of lug bolt receiving holes 36 spaced circumferentially around the pilot aperture 34.

The lug bolt receiving holes 36 receive lug bolts and nuts (not shown) for securing the wheel 10 on an axle (not shown) of a vehicle. The inboard portion 33 ofthe disc 14 defines a shoulder 38 for receiving the outboard end 25 ofthe rim 12.

Preferably, as shown in Fig. 2, the shoulder 38 is formed generally radially inwardly a desired distance Y from an outer surface 33A of the inboard portion 33 of the disc 14 which is generally the same as a thickness T of the rim 12 in the outboard end 25 thereof. As a result, when the rim 12 and disc 14 are

assembled, a generally continuous, uninterrupted outer surface 26A of the outboard tire bead seat 26 is defined between an adjacent outer surface 25A of the outboard end 25 ofthe rim 12 and an outer surface 33A ofthe inboard portion 33 of the disc 14. Alternatively, the distance Y can be less than or greater than the thickness T. As will be discussed, the shoulder 38 of the disc 14 preferably defines an outer diameter which is slightly greater than an inner diameter defined by an inner surface ofthe outboard end 25 ofthe rim 12 so as to provide an interference fit therewith when the rim 12 and the disc 14 are assembled Turning now to Figs. 2 and 13, the method for joining the rim 12 to the disc 14 to produce the vehicle wheel 10 of this invention will be discussed. As shown therein, in optional step 298, the rim 12 is heated to a desired temperature in order to allow the rim 12 to be expanded and slipped onto the disc 14 in an interference fit therewith. Typically, the temperature is in the range from about 100"F (38"C) to about 300"F (150"C) for aluminium, and in the range from about 100"F (38"C) to about 600"F (315"C) for steel. Following this, in step 300, the heated rim 12 (if optional step 298 is performed) and the disc 14 are assembled by positioning the outboard end 25 of the rim 12 on the shoulder 38 of the disc 14 in a desired position.

Next, in the illustrated embodiment, an end 40 of a NVEBW gun 42 is positioned a desired generally vertical distance A from the outer surface 26A outboard tire bead seat 26 of the wheel 10 and in a generally parallel relationship therewith. Alternatively, the end 40 of the NVEBW gun 42 may be oriented at an angle relative to the outer surface 26A of the outboard tire bead seat 26 of the wheel 10, or the outer surface 26A of the outboard tire bead seat 16 of the wheel 10 may be oriented at an angle relative to the end 40 of the NVEBW gun 42.

Generally, the vertical distance A is in the range from about 1/8 inch to about 1 inch in order to produce a desired NVEBW width or working angle B

which is generally in the range from about 10° to about 80". Preferably, the vertical distance A is in the range from about 1/4 inch to about 3/4 inch in order to produce a desired NVEBW working angle B in the range from about 10° to about 45". More preferably, the vertical distance A is approximately 1/2 inch to produce a desired NVEBW working angle B of approximately 20°. However, depending upon the particular type of vehicle wheel construction, the vertical distance A and/or the NVEBW working angle B may be different from those disclosed herein.

Then, during optional step 304, the NVEBW gun 42 is actuated in order to "partially" join the rim 12 to the disc 14. To accomplish this, the NVEBW gun 42 is actuated to produce a plurality of non-vacuum electron beam tack welds as the rim 12 and the disc 14 are rotated relative to the NVEBW gun 42.

The number of tack welds produced during optional step 304 can be as few as two or as many as ten, and the tack welds are preferably evenly spaced circumferentially around the rim 12 and the disc 14. More preferably, the number of tack welds produced during optional step 304 is between three to six.

Also, the tack welds are preferably produced as the rim 12 and the disc 14 are rotated approximately at least a full revolution (360°) at a desired rate of revolution during optional step 304. Alternatively, during optional tack welding step 304, the rim 12 and the disc 14 can be rotated less than a full revolution, and/or the NVEBW gun 42 can be rotated relative to the rim 12 and the disc 14, or the NVEBW gun 42 and the rim 12 and the disc 14 can be rotated. Also, the tacks welds produced during optional step 304 can be produced by other welding processes, such as for example, a gas metal arc welding process, a laser welding process, or a vacuum electron beam welding process.

Next, in step 306, the NVEBW gun 42 is actuated in order to join the rim 12 to the disc 14 to produce the vehicle wheel 50. To accomplish this, the NVEBW gun 42 is actuated to produce a single continuous weld (the weld being

shown in phantom at 40 in Fig. 2) as the partially welded rim 12 and disc 14 (if optional step 302 is performed) are rotated. Preferably the rim 12 and the disc 14 are rotated at least a full revolution (360°) at a desired rate of revolution during step 306. More preferably, during step 306, in order to ensure that the weld 44 completely extends around the entire circumference of the wheel 10, the rim 12 and the disc 14 are rotated a full revolution plus an additional degree of revolution to allow overlap of the weld 44. Generally, the additional degree of revolution is approximately 30° and thereby produces a single continuous weld 44 of approximately 390". However, the additional degree of revolution may be different than described if so desired. Also, depending upon the particular vehicle wheel construction, the rim 12 and the disc 14 can be rotated less than a full revolution during step 306.

Preferably, the same NVEBW gun 42 is used to produce both the tack welds of optional step 304 and the weld of step 306. The NVEBW gun 42 is preferably a two stage gun and operates by generating an electron beam in a high vacuum in the upper stage (not shown) of the NVEBW gun 42 and directs the beam through a low vacuum in the lower stage of the NVEBW gun 42. The electron beam leaves the NVEBW gun 42 through a gun orifice (not shown) having a desired diameter and produces a beam width (generally shown in phantom at 40A in Fig. 2). The beam width 40A as it strikes the associated surfaces of the rim 12 and the disc 14 is dependent on the vertical distance A the NVWBW gun 42 is located therefrom. Thus, as discussed above, the vertical distance A is selected to produce a desired NVEBW width or working angle B.

As a result, the weld 44 sufficiently penetrates in both a radial direction and an axial direction into the rim 12 and the disc 14 without causing weld burn through in the weldment region. Also, helium gas is preferably used to flood the lower orifice of the NVEBW gun 42 during the welding processes of steps 304 and 306.

Turning now to Fig. 3, there is illustrated a sectional view of a portion of a second embodiment of an improved vehicle wheel, indicated generally at 50, in accordance with the present invention. The vehicle wheel 50 includes a rim 52 and a full face wheel disc 54.

The rim 52 is a fabricated rim preferably constructed of aluminum or other alloys thereof. Alternatively, the rim 52 may be formed from other metals, such as for example, steel. The rim 52 includes an inboard tire bead seat retaining flange 60, an inboard tire bead seat 62, an outboard end 65 which forms a portion of a generally axially extending well 64.

The disc 54 is preferably a cast disc constructed of aluminum or other alloys thereof. Alternatively, the disc 54 can be forged, fabricated, or otherwise formed and/or can be formed from other metals, such as for example, magnesium and steel. Also, for manufacturing purposes, the rim 12 and the disc 14 are preferably formed from the same kind of metal; however, the rim 12 and the disc 14 may be formed from different metals if desired.

The disc 14 includes an outer annular flange 72 which forms an outboard tire bead seat retaining flange of the wheel 50, an outboard tire bead seat 74, and an inboard portion 75 which forms a portion of the well 64. The inboard portion 75 of the disc 54 defines a shoulder 78 for receiving the outboard end 65 of the rim 52. Preferably, as shown in Fig. 4, the shoulder 78 is formed generally radially inwardly a desired distance Y1 from an outer surface 75A ofthe inboard portion 75 of the disc 54 which is generally the same as a thickness T1 of the rim 52 in the outboard end 65 thereof. As a result, when the rim 52 and disc 54 are assembled, a generally continuous, uninterrupted outer surface 64A of the well 64 is defined between an adjacent outer surface 65A of the outboard end 65 of the rim 52 and an outer surface 75A ofthe inboard portion 75 ofthe disc 14.

Alternatively, the distance Y1 can be less than or greater than the thickness T1.

As will be discussed, the shoulder 78 of the disc 54 preferably defines an outer

diameter which is slightly greater than an inner diameter defined by an inner surface of the outboard end 65 of the rim 52 so as to provide an interference fit therewith when the rim 52 and the disc 54 are assembled Turning now to Figs. 4 and 13, the method for joining the rim 52 to the disc 54 to produce the vehicle wheel 50 of this invention will be discussed. As shown therein, in optional step 298, the rim 52 is heated to a desired temperature in order to allow the rim 52 to be expanded and slipped onto the disc 54 in an interference fit therewith. Typically, the temperature is in the range from about 100"F (38"C) to about 300"F (150"C) for aluminium, and in the range from about 100"F (38"C) to about 600"F (315"C) for steel. Following this, in step 300, the heated rim 52 (if optional step 298 is performed) and the disc 54 are assembled by positioning the outboard end 65 of the rim 52 on the shoulder 78 of the disc 54 in a desired position.

Next, in the illustrated embodiment, the end 40 of the NVEBW gun 42 is positioned a desired generally vertical distance C from the outer surface 64A of the well 64 of the wheel 50 and in a generally parallel relationship therewith during step 302. Alternatively, the end 40 of the NVEBW gun 42 may be oriented at an angle relative to the outer surface 64A of the well 64 of the wheel 50, or the outer surface 64A of the well 64 of the wheel 50 may be oriented at an angle relative to the end 40 of the NVEBW gun 42.

Generally, the vertical distance C is in the range from about 1/8 inch to about 1 inch in order to produce a desired NVEBW width or working angle D which is generally in the range from about 10° to about 80". Preferably, the vertical distance C is in the range from about 1/4 inch to about 3/4 inch in order to produce a desired NVEBW working angle D in the range from about 10° to about 45". More preferably, the vertical distance C is approximately 1/2 inch to produce a desired NVEBW working angle D of approximately 20°. However, depending upon the particular type of vehicle wheel construction, the vertical

distance C and/or the NVEBW working angle D may be different from those disclosed herein.

Then, during optional step 304, the NVEBW gun 42 is actuated in order to "partially" join the rim 52 to the disc 54. To accomplish this, the NVEBW gun 42 is actuated to produce a plurality of non-vacuum electron beam tack welds as the rim 52 and the disc 54 are rotated relative to the NVEBW gun 42.

The number of tack welds produced during optional step 304 can be as few as two or as many as ten, and the tack welds are preferably evenly spaced circumferentially around the rim 52 and the disc 54. More preferably, the number of tack welds produced during optional step 304 is between three to six.

Also, the tack welds are preferably produced as the rim 52 and the disc 54 are rotated approximately at least a full revolution (3600) at a desired rate of revolution during optional step 304. Alternatively, during optional tack welding step 304, the rim 52 and the disc 54 can be rotated less than a full revolution, and/or the NVEBW gun 42 can be rotated relative to the rim 52 and the disc 54, or the NVEBW gun 42 and the rim 52 and the disc 54 can be rotated. Also, the tacks welds produced during optional step 304 can be produced by other welding processes, such as for example, a gas metal arc welding process, a laser welding process, or a vacuum electron beam welding process.

Next, in step 306, the NVEBW gun 42 is actuated in order to join the rim 52 to the disc 54 to produce the vehicle wheel 50. To accomplish this, the NVEBW gun 42 is actuated to produce a single continuous weld (the weld being shown in phantom at 80 in Fig. 4) as the partially welded rim 52 and disc 54 (if optional step 302 is performed) are rotated. Preferably the rim 52 and the disc 54 are rotated at least a full revolution (360°) at a desired rate of revolution during step 306. More preferably, during step 306, in order to ensure that the weld 80 completely extends around the entire circumference of the wheel 50, the rim 52 and the disc 54 are rotated a full revolution plus an additional degree of

revolution to allow overlap of the weld 80. Generally, the additional degree of revolution is approximately 30° and thereby produces a single continuous weld 80 of approximately 390". However, the additional degree of revolution may be different than described if so desired. Also, depending upon the particular vehicle wheel construction, the rim 52 and the disc 54 can be rotated less than a full revolution during step 306. Preferably, the same NVEBW gun 42 is used to produce both the tack welds of optional step 304 and the weld of step 306.

Referring now to Fig. 5, there is illustrated a sectional view of a portion of a third embodiment of an improved vehicle wheel, indicated generally at 90, in accordance with the present invention. The vehicle wheel includes a rim 92 and a full face wheel disc 94. The rim 92 is a fabricated rim preferably constructed of aluminum or other alloys thereof. Alternatively, the rim 92 can be formed from other metals, such as for example, steel. The rim 92 includes an inboard tire bead seat retaining flange 100, an inboard tire bead seat 102, a generally axially extending well 104, and an outboard end 105 which forms a portion of an outboard tire bead seat 106.

The disc 94 is preferably a cast disc constructed of aluminum or other alloys thereof. Alternatively, the disc 94 can be forged, fabricated, or otherwise formed, and/or can be formed from other metals, such as for example, magnesium and steel. Also, for manufacturing purposes, the rim 92 and the disc 94 are preferably formed from the same kind of metal; however, the rim 92 and the disc 94 may be formed from different metals if desired.

The disc 94 includes an outer annular flange 112 which forms an outboard tire bead seat retaining flange 128 of the wheel 90, and an inboard portion 113 which forms a portion of the outboard tire bead seat 106. The inboard portion 113 of the disc 94 defines a shoulder 118 for receiving the outboard end 105 of the rim 92.

Preferably, as shown in Fig. 6, the shoulder 118 is formed generally radially inwardly a desired distance Y2 from an outer surface 1 13A ofthe inboard portion 133 of the disc 94 which is generally the same as a thickness T2 of the rim 92 in the outboard end 105 thereof. As a result, when the rim 92 and disc 94 are assembled, a generally continuous, uninterrupted outer surface 1 06A of the outboard tire bead seat 106 is defined between an adjacent outer surface 105A of the outboard end 105 of the rim 92 and an outer surface 1 13A of the inboard portion 113 of the disc 94. Alternatively, the distance Y2 can be less than or greater than the thickness T2. As will be discussed, the shoulder 118 of the disc 94 preferably defines an outer diameter which is slightly greater than an inner diameter defined by an inner surface of the outboard end 105 of the rim 92 so as to provide an interference fit therewith when the rim 92 and the disc 94 are assembled Turning now to Figs. 6 and 13, the method for joining the rim 92 to the disc 94 to produce the vehicle wheel 90 of this invention will be discussed. As shown therein, in optional step 298, the rim 92 is heated to a desired temperature in order to allow the rim 92 to be expanded and slipped onto the disc 94 in an interference fit therewith. Typically, the temperature is in the range from about 100"F (38"C) to about 300"F (150"C) for aluminum, and in the range from about 100"F (38"C) to about 600"F (315°C) for steel. Alternatively, only one of the rim 92 and the disc 94 can be heated during optional step 298. Following this, in step 300, the heated rim 92 (if optional step 298 is performed) and the disc 94 are assembled by positioning the outboard end 105 of the rim 92 on the shoulder 118 of the disc 94 in a desired position.

Next, in the illustrated embodiment, the end 40 of the NVEBW gun 42 is positioned a desired generally vertical distance E from the outer surface 1 06A outboard tire bead seat 106 of the wheel 90 and in a generally parallel relationship therewith. Alternatively, the end 40 of the NVEBW gun 42 may be

oriented at an angle relative to the outer surface 1 06A of the outboard tire bead seat 106 of the wheel 90, or the outer surface 106A of the outboard tire bead seat 106 of the wheel 90 may be oriented at an angle relative to the end 40 of the NVEBW gun 42.

Generally, the vertical distance E is in the range from about 1/8 inch to about 1 inch in order to produce a desired NVEBW width or working angle F which is generally in the range from about 10° to about 80". Preferably, the vertical distance E is in the range from about 1/4 inch to about 3/4 inch in order to produce a desired NVEBW working angle F in the range from about 10° to about 45°. More preferably, the vertical distance E is approximately 1/2 inch to produce a desired NVEBW working angle F of approximately 20°. However, depending upon the particular type of vehicle wheel construction, the vertical distance E and/or the NVEBW working angle F may be different from those disclosed herein.

Then, during optional step 304, the NVEBW gun 42 is actuated in order to "partially" join the rim 92 to the disc 94. To accomplish this, the NVEBW gun 42 is actuated to produce a plurality of non-vacuum electron beam tack welds as the rim 92 and the disc 94 are rotated relative to the NVWBW gun 42.

The number of tack welds produced during optional step 304 can be as few as two or as many as ten, and the tack welds are preferably evenly spaced circumferentially around the rim 92 and the disc 94. More preferably, the number of tack welds produced during optional step 304 is between three to six.

Also, the tack welds are preferably produced as the rim 92 and the disc 94 are rotated approximately at least a full revolution (360°) at a desired rate of revolution during optional step 304. Alternatively, during optional tack welding step 304, the rim 92 and the disc 94 can be rotated less than a full revolution, and/or the NVEBW gun 42 can be rotated relative to the rim 92 and the disc 94, or the NVEBW gun 42 and the rim 92 and the disc 94 can be rotated. Also, the

tacks welds produced during optional step 304 can be produced by other welding processes, such as for example, a gas metal arc welding process, a laser welding process, or a vacuum electron beam welding process.

Next, in step 306, the NVEBW gun 42 is actuated in order to join the rim 92 to the disc 94 to produce the vehicle wheel 90. To accomplish this, the NVEBW gun 42 is actuated to produce a single continuous weld (the weld being shown in phantom at 114 in Fig. 2) as the partially welded rim 92 and disc 94 (if optional step 302 is performed) are rotated. Preferably the rim 92 and the disc 94 are rotated at least a full revolution (3600) at a desired rate of revolution during step 306. More preferably, during step 306, in order to ensure that the weld 114 completely extends around the entire circumference of the wheel 90, the rim 92 and the disc 94 are rotated a full revolution plus an additional degree of revolution to allow overlap of the weld 114. Generally, the additional degree of revolution is approximately 30° and thereby produces a single continuous weld 114 of approximately 390". However, the additional degree of revolution may be different than described if so desired. Also, depending upon the particular vehicle wheel construction, the rim 92 and the disc 94 can be rotated less than a full revolution during step 306. Preferably, the same NVEBW gun 42 is used to produce both the tack welds of optional step 304 and the weld of step 306.

Turning now to Fig. 7, there is illustrated a fourth view of a portion of a second embodiment of an improved vehicle wheel, indicated generally at 120, in accordance with the present invention. The vehicle wheel 120 is a "well attached" vehicle wheel 120 and includes a rim 122 and a full face wheel disc 124. The rim 122 is a fabricated rim preferably constructed of aluminum or other alloys thereof. Alternatively, the rim 122 can be formed from other metals, such as for example, steel. The rim 122 includes an inboard tire bead seat retaining flange 130, an inboard tire bead seat 132, an outboard end 133 which forms a portion of a generally axially extending well 134.

The disc 124 is preferably a fabricated disc constructed of aluminum or other alloys thereof. Alternatively, the disc 124 can be forged, cast. or otherwise formed, and/or can be formed from other metals, such as for example, magnesium and steel. Also, for manufacturing purposes, the rim 122 and the disc 124 are preferably formed from the same kind of metal; however, the rim 122 and the disc 124 may be formed from different metals if desired.

The disc 124 includes an outer annular flange 142 which forms an outboard tire bead seat retaining flange 136 of the wheel 120, an outboard tire bead seat 144, and an inboard portion 145 which forms a portion of the well 134.

Preferably, as shown in Fig. 7, the inboard portion 145 ofthe disc 124 defines a generally constant thickness T5 which is generally the same as a thickness T4 defined by the outboard end 133 of the rim 122. As a result, when the rim 122 and disc 124 are assembled, a generally continuous, uninterrupted outer surface 134A of the well 134 is defined between an adjacent outer surface 133A of the outboard end 133 ofthe rim 122 and an outer surface 145A ofthe inboard portion 145 of the disc 124. Alternatively, the thicknesses T4 and T5 can be other than illustrated.

Turning now to Figs. 8 and 13, the method for joining the rim 122 to the disc 124 to produce the vehicle wheel 120 ofthis invention will be discussed. In step 300, the rim 122 and the disc 124 are assembled by positioning an end 133B of the outboard end 133 of the rim 122 adjacent an end 145B of the inboard portion 145 of the disc 124 in a desired position. Next, in the illustrated embodiment, the end 40 of the NVEBW gun 42 is positioned a desired generally vertical distance G from the outer surface 134A of the well 134 of the wheel 120 and in a generally parallel relationship therewith during step 302. Alternatively, the end 40 of the NVEBW gun 42 may be oriented at an angle relative to the outer surface 134A of the well 134 of the wheel 120, or the outer surface 134A

of the well 134 of the wheel 120 may be oriented at an angle relative to the end 40 of the NVEBW gun 42.

Generally, the vertical distance G is in the range from about 1/8 inch to about 1 inch in order to produce a desired NVEBW width or working angle H which is generally in the range from about 10° to about 80". Preferably, the vertical distance G is in the range from about 1/4 inch to about 3/4 inch in order to produce a desired NVEBW working angle H in the range from about 10° to about 45°. More preferably, the vertical distance G is approximately 1/2 inch to produce a desired NVEBW working angle H of approximately 20°. However, depending upon the particular type of vehicle wheel construction, the vertical distance G and/or the NVEBW working angle H may be different from those disclosed herein.

Then, during optional step 304, the NVEBW gun 42 is actuated in order to "partially" join the rim 122 to the disc 124. To accomplish this, the NVEBW gun 42 is actuated to produce a plurality of non-vacuum electron beam tack welds as the rim 122 and the disc 124 are rotated relative to the NVWBW gun 42. The number of tack welds produced during optional step 304 can be as few as two or as many as ten, and the tack welds are preferably evenly spaced circumferentially around the rim 122 and the disc 124. More preferably, the number of tack welds produced during optional step 304 is between three to six.

Also, the tack welds are preferably produced as the rim 122 and the disc 124 are rotated approximately at least a full revolution (360°) at a desired rate of revolution during optional step 304. Alternatively, during optional tack welding step 304, the rim 122 and the disc 124 can be rotated less than a full revolution, and/or the NVEBW gun 42 can be rotated relative to the rim 122 and the disc 124, or the NVEBW gun 42 and the rim 122 and the disc 124 can be rotated.

Also, the tacks welds produced during optional step 304 can be produced by

other welding processes, such as for example, a gas metal arc welding process, a laser welding process, or a vacuum electron beam welding process.

Next, in step 306, the NVEBW gun 42 is actuated in order to join the rim 122 to the disc 124 to produce the vehicle wheel 120. To accomplish this, the NVEBW gun 42 is actuated to produce a single continuous weld (the weld being shown in phantom at 150 in Fig. 8) as the partially welded rim 122 and disc 124 (if optional step 302 is performed) are rotated. Preferably the rim 122 and the disc 124 are rotated at least a full revolution (360°) at a desired rate of revolution during step 306. More preferably, during step 306, in order to ensure that the weld 150 completely extends around the entire circumference ofthe wheel 120, the rim 122 and the disc 124 are rotated a full revolution plus an additional degree of revolution to allow overlap of the weld 150. Generally, the additional degree of revolution is approximately 30° and thereby produces a single continuous weld 150 of approximately 390". However, the additional degree of revolution may be different than described if so desired. Also, depending upon the particular vehicle wheel construction, the rim 122 and the disc 124 can be rotated less than a full revolution during step 306. Preferably, the same NVEBW gun 42 is used to produce both the tack welds of optional step 304 and the weld of step 306.

Referring now to Fig. 9, there is illustrated a sectional view of a portion of a fifth embodiment of an improved vehicle wheel, indicated generally at 160, in accordance with the present invention. The vehicle wheel 160 is a "bead seat attached" vehicle wheel 160 and includes a rim 162 and a full face wheel disc 164. The rim 162 is a fabricated rim preferably constructed of aluminum or other alloys thereof. Alternatively, the rim 162 can be formed from other metals, such as for example, steel. The rim 162 includes an inboard tire bead seat retaining flange 170, an inboard tire bead seat 172, a generally axially extending

well 174, and an outboard end 175 which forms a portion of an outboard tire bead seat 176.

The disc 164 is preferably a cast disc constructed of aluminum or other alloys thereof. Alternatively, the disc 164 can be forged, fabricated, or otherwise formed, and/or can be formed from other metals, such as for example, magnesium and steel. Also, for manufacturing purposes, the rim 162 and the disc 164 are preferably formed from the same kind of metal; however, the rim 162 and the disc 164 may be formed from different metals if desired.

The disc 164 includes an outer annular flange 188 which forms an outboard tire bead seat retaining flange 178 of the wheel 160, and an inboard portion 183 which forms a portion of the outboard tire bead seat 176. Preferably, as shown in Fig. 10, the inboard portion 183 of the disc 164 defines a generally constant thickness T6 which is generally the same as a thickness T7 defined by the outboard end 175 of the rim 162. As a result, when the rim 162 and disc 164 are assembled, a generally continuous, uninterrupted outer surface 1 76A of the outboard tire bead seat 176 is defined between an adjacent outer surface 175A of the outboard end 175 of the rim 162 and an outer surface 183A of the inboard portion 183 of the disc 164. Alternatively, the thicknesses T6 and T7 can be other than illustrated.

Turning now to Figs. 10 and 13, the method for joining the rim 162 to the disc 164 to produce the vehicle wheel 160 of this invention will be discussed. In step 300, the rim 162 and disc 164 are assembled by positioning an end 175B of the outboard end 175 of the rim 162 adjacent an end 183B of the inboard portion 183 of the disc 164 in a desired position. Next, in the illustrated embodiment, the end 40 of the NVEBW gun 42 is positioned a desired generally vertical distance I from the outer surface 176A of the outboard tire bead seat 176 of the wheel 160 and in a generally parallel relationship therewith during step 302.

Alternatively, the end 40 of the NVEBW gun 42 may be oriented at an angle

relative to the outer surface 176A of the outboard tire bead seat 176 of the wheel 120, or the outer surface 176A of the outboard tire bead seat 176 of the wheel 160 may be oriented at an angle relative to the end 40 of the NVEBW gun 42.

Generally, the vertical distance I is in the range from about 1/8 inch to about 1 inch in order to produce a desired NVEBW width or working angle J which is generally in the range from about 10° to about 80". Preferably, the vertical distance I is in the range from about 1/4 inch to about 3/4 inch in order to produce a desired NVEBW working angle J in the range from about 10° to about 45°. More preferably, the vertical distance I is approximately 1/2 inch to produce a desired NVEBW working angle J of approximately 20°. However, depending upon the particular type of vehicle wheel construction, the vertical distance I and/or the NVEBW working angle J may be different from those disclosed herein.

Then, during optional step 304, the NVEBW gun 42 is actuated in order to "partially" join the rim 162 to the disc 164. To accomplish this, the NVEBW gun 42 is actuated to produce a plurality of non-vacuum electron beam tack welds as the rim 162 and the disc 164 are rotated relative to the NVWBW gun 42. The number of tack welds produced during optional step 304 can be as few as two or as many as ten, and the tack welds are preferably evenly spaced circumferentially around the rim 162 and the disc 164. More preferably, the number of tack welds produced during optional step 304 is between three to six.

Also, the tack welds are preferably produced as the rim 162 and the disc 164 are rotated approximately at least a full revolution (360°) at a desired rate of revolution during optional step 304. Alternatively, during optional tack welding step 304, the rim 162 and the disc 164 can be rotated less than a full revolution, and/or the NVEBW gun 42 can be rotated relative to the rim 162 and the disc 164, or the NVEBW gun 42 and the rim 162 and the disc 164 can be rotated.

Also, the tacks welds produced during optional step 304 can be produced by

other welding processes, such as for example, a gas metal arc welding process, a laser welding process, or a vacuum electron beam welding process.

Next, in step 306, the NVEBW gun 42 is actuated in order to join the rim 162 to the disc 164 to produce the vehicle wheel 160. To accomplish this, the NVEBW gun 42 is actuated to produce a single continuous weld (the weld being shown in phantom at 190 in Fig. 10) as the partially welded rim 162 and disc 164 (if optional step 302 is performed) are rotated. Preferably the rim 162 and the disc 164 are rotated at least a full revolution (360°) at a desired rate of revolution during step 306. More preferably, during step 306, in order to ensure that the weld 190 completely extends around the entire circumference of the wheel 160, the rim 162 and the disc 164 are rotated a full revolution plus an additional degree of revolution to allow overlap of the weld 190. Generally, the additional degree of revolution is approximately 30° and thereby produces a single continuous weld 190 of approximately 3900. However, the additional degree of revolution may be different than described if so desired. Also, depending upon the particular vehicle wheel construction, the rim 162 and the disc 164 can be rotated less than a full revolution during step 306. Preferably, the same NVEBW gun 42 is used to produce both the tack welds of optional step 304 and the weld of step 306.

Referring now to Fig. 11, there is illustrated a sectional view of a portion of a sixth embodiment of an improved vehicle wheel, indicated generally at 200, in accordance with the present invention. The vehicle wheel 160 is a "well attached" vehicle wheel 200 and includes an outer "full" rim 202 and an inner wheel disc 204. The rim 202 is a fabricated rim preferably constructed of aluminum or other alloys thereof. Alternatively, the rim 202 can be formed from other metals, such as for example, steel. The rim 202 includes an inboard tire bead seat retaining flange 210, an inboard tire bead seat 212, a generally axially

extending well 214, an outboard tire bead seat 216, and an outboard tire bead seat retaining flange 218.

The disc 204 is preferably a fabricated disc constructed of aluminum or other alloys thereof. Alternatively, the disc 204 can be forged, cast, or otherwise formed, and/or can be formed from other metals, such as for example, magnesium and steel. Also, for manufacturing purposes, the rim 202 and the disc 204 are preferably formed from the same kind of metal; however, the rim 202 and the disc 204 may be formed from different metals if desired. The disc 204 includes an outer annular flange 222 and an inner mounting portion 224.

Turning now to Figs. 12 and 13, the method for joining the rim 202 to the disc 204 to produce the vehicle wheel 200 of this invention will be discussed.

As shown therein, in optional step 298, the rim 202, the disc 204, or both are heated to a desired temperature depending upon the particular fit of the rim 202 to the disc 204. Typically, the temperature is in the range from about 100"F (38"C) to about 300"F (150"C) for aluminum, and in the range from about 100"F (38"C) to about 600"F (315"C) for steel. Following this, in step 300, the rim 202 and the disc 204 are assembled by positioning an outer surface 222A of the outer annular flange 222 ofthe disc 204 adjacent an inner surface 214A ofthe well 214 of the rim 202 in a desired position.

Next, in the illustrated embodiment, the end 40 of the NVEBW gun 42 is positioned a desired vertical distance K from a midpoint denoted at a point N on an end surface 222B of the disc 204 with the gun 42 oriented at a desired angle M relative to the end surface 222B of the disc 204. Alternatively, the end 40 of the NVEBW gun 42 can be oriented other than illustrated. Generally, the angle M is in the range from about 10° to about 80°, and the vertical distance K is in the range from about 1/8 inch to about 1 inch in order to produce a desired NVEBW width or working angle L which is generally in the range from about 10° to about 80". Preferably, the angle M is in the range from about 30° to about

60°, and the vertical distance K is in the range from about 1/4 inch to about 3/4 inch in order to produce a desired NVEBW working angle L in the range from about 10° to about 45". More preferably, the angle M is approximately 45" and the vertical distance K is approximately 1/2 inch to produce a desired NVEBW working angle L of approximately 20°. However, depending upon the particular type of vehicle wheel construction, the vertical distance K, and/or the NVEBW working angle L, and or the angle M may be different from those disclosed herein. As a result, weld burn through is minimized.

Then, during optional step 304, the NVEBW gun 42 is actuated in order to "partially" join the rim 202 to the disc 204. To accomplish this, the NVEBW gun 42 is actuated to produce a plurality of non-vacuum electron beam tack welds as the rim 202 and the disc 204 are rotated relative to the NVWBW gun 42. The number of tack welds produced during optional step 304 can be as few as two or as many as ten, and the tack welds are preferably evenly spaced circumferentially around the rim 202 and the disc 204. More preferably, the number of tack welds produced during optional step 304 is between three to six.

Also, the tack welds are preferably produced as the rim 202 and the disc 204 are rotated approximately at least a full revolution (360°) at a desired rate of revolution during optional step 304. Alternatively, during optional tack welding step 304, the rim 202 and the disc 204 can be rotated less than a full revolution, and/or the NVEBW gun 42 can be rotated relative to the rim 202 and the disc 204, or the NVEBW gun 42 and the rim 202 and the disc 204 can be rotated.

Also, the tacks welds produced during optional step 304 can be produced by other welding processes, such as for example, a gas metal arc welding process, a laser welding process, or a vacuum electron beam welding process.

Next, in step 306, the NVEBW gun 42 is actuated in order to join the rim 202 to the disc 204 to produce the vehicle wheel 200. To accomplish this, the NVEBW gun 42 is actuated to produce a single continuous weld (the weld being

shown in phantom at 230 in Fig. 12) as the partially welded rim 202 and disc 204 (if optional step 302 is performed) are rotated. Preferably the rim 202 and the disc 204 are rotated at least a full revolution (360°) at a desired rate of revolution during step 306. More preferably, during step 306, in order to ensure that the weld 230 completely extends around the entire circumference of the wheel 200, the rim 202 and the disc 204 are rotated a full revolution plus an additional degree of revolution to allow overlap of the weld 230. Generally, the additional degree of revolution is approximately 30° and thereby produces a single continuous weld 230 of approximately 390". However, the additional degree of revolution may be different than described if so desired. Also, depending upon the particular vehicle wheel construction, the rim 202 and the disc 204 can be rotated less than a full revolution during step 306. Preferably, the same NVEBW gun 42 is used to produce both the tack welds of optional step 304 and the weld of step 306.

One advantage of this invention is that NVEBW process of this invention is not sensitive to atmospheric conditions, such as humidity and temperature.

Also, the NVEBW process of this invention does not require the use of a shielding gas in the air gap between the gun and the adjacent surface ofthe wheel. However, a shielding gas, such as for example, 100% helium can be used to improve the surface texture of the weld. Also, the NVEBW process of this invention uses less energy, provides a good quality weld, and inputs less heat into the associated wheel compared to a GMAW process. In addition, the NVEBW process of this invention results in minimal porosity to the wheel in the weld region, has no spatter of the weld, and has minimal moving parts and fewer consumable parts, such as no welding tips, weld wire, or shielding gas, compared to a GMAW process. Further, the NVEBW process of this invention is considerably faster than a GMAW process.

Although this invention has been illustrated and described in connection with the particular vehicle wheels 10, 50, 90, 120, 160, and 200 disclosed herein, it will be appreciated that the present invention can be used in conjunction with other types of vehicle wheels.

In accordance with the provisions of the patents statues, the principle and mode of operation of this invention have been described and illustrated in its preferred embodiments. However, it must be understood that the invention may be practiced otherwise than as specifically explained and illustrated without departing from the scope or spirit of the attached claims.