Optimization of Electrical Resistance Spot Welding and Comparison with Friction Stir Spot Welding of AA2024-T3 Aluminum Alloy Joints

2017 ◽  
Vol 4 (2) ◽  
pp. 1762-1771 ◽  
Author(s):  
R. Karthikeyan ◽  
V. Balasubramaian
Keyword(s):  
Aluminum Alloy ◽  
Electrical Resistance ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Friction Stir Spot Welding ◽  
Friction Stir ◽  
Resistance Spot

scholarly journals Friction Stir Resistance Spot Welding of Aluminum Alloy to Advanced High Strength Steel

2018 ◽  
Vol 140 (11) ◽  
Author(s):  
Kai Chen ◽  
Xun Liu ◽  
Jun Ni
Keyword(s):  
Aluminum Alloy ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Plastic Material ◽  
Welding Process ◽  
Electrical Current ◽  
Atomic Diffusion ◽  
Friction Stir ◽  
Resistance Spot ◽  
Welding Force

A hybrid friction stir resistance spot welding (RSW) process is applied for joining aluminum alloy 6061 to TRIP 780 steel. Compared with conventional RSW, the applied current density is lower and the welding process remains in the solid state. Compared with conventional friction stir spot welding (FSSW) process, the welding force is reduced and the dissimilar material joint strength is increased. The electrical current is applied in both a pulsed and direct form. With the equal amount of energy input, the approximately same force reduction indicates that the electro-plastic material softening effect is insignificant during FSSW process. The welding force is reduced mainly due to the resistance heating induced thermal softening of materials. With the application of electrical current, a wider aluminum flow pattern is observed in the thermo-mechanically affected zone (TMAZ) of weld cross sections and a more uniform hook is formed at the Fe/Al interface. This implies that the aluminum material flow is enhanced. Moreover, the Al composition in the Al–Fe interfacial layer is higher, which means the atomic diffusion is accelerated.

Comparative Study of Spot Welding and Firiction Stir Spot Welding of Al 2024-T3

2018 ◽  
Vol 786 ◽  
pp. 104-118
Author(s):  
M.H. Fahmy ◽  
Hamed Abdel-Aleem ◽  
M.R. Elkousy ◽  
N. M. Abdel-Elraheem
Keyword(s):  
Shear Strength ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Dendritic Structure ◽  
Friction Stir Spot Welding ◽  
Stir Zone ◽  
Tensile Shear ◽  
Friction Stir ◽  
Resistance Spot ◽  
Aluminum Alloy 2024

This investigation is performed to compare the resistance spot welding (RSW) of aluminum alloy (2024-T3) with friction stir spot welding (FSSW) techniques. In this work, parameters of both resistance spot welding (RSW) and friction stir spot welding (FSSW) techniques were optimized and the optimum welding variables for both techniques were obtained. For FSSW, the tensile shear strength increased with increasing probe length, tool rotational speed and tool holding time. Tensile shear force value of RSW is about 66% of that of FSSW. This is explained by the coarse dendritic structure in resistance spot welding compared to the plastically deformed stir zone and heat affected zone in FSSW. The ratio of nugget shear strength of RSW and FSSW to base metal is about 71% and 149% respectively. The maximum hardness was obtained in stir zone at the surface of the tool. Very fine grain size of about 4 microns was obtained in stir zone followed by elongated and rotated grains in TMAZ where dynamic recrystallization did not occur.

Dissimilar metals joining of steel and aluminum alloy by resistance spot welding

2014 ◽  
Vol 32 (2) ◽  
pp. 83-94 ◽  
Author(s):  
Kenji MIYAMOTO ◽  
Shigeyuki NAKAGAWA ◽  
Chika SUGI ◽  
Kenji TSUSHIMA ◽  
Shingo IWATANI ◽  
...  
Keyword(s):  
Aluminum Alloy ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Dissimilar Metals ◽  
Resistance Spot

scholarly journals Effect of Resistance Spot Welding Parameters on AA1100 Aluminum Alloy and SGACD Zinc coated Lap Joint Properties

2015 ◽  
Vol 3 (1) ◽  
pp. 153-160 ◽  
Author(s):  
Sakchai Chantasri ◽  
Pramote Poonnayom ◽  
Jesada Kaewwichit ◽  
Waraporn Roybang ◽  
Kittipong Kimapong
Keyword(s):  
Aluminum Alloy ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Welding Parameters ◽  
Lap Joint ◽  
Resistance Spot ◽  
Joint Properties ◽  
Aa1100 Aluminum Alloy

scholarly journals Resistance Spot Welding Optimization Based on Artificial Neural Network

2014 ◽  
Vol 2014 ◽  
pp. 1-6 ◽  
Author(s):  
Thongchai Arunchai ◽  
Kawin Sonthipermpoon ◽  
Phisut Apichayakul ◽  
Kreangsak Tamee
Keyword(s):  
Neural Network ◽  
Artificial Neural Network ◽  
Shear Strength ◽  
Aluminum Alloy ◽  
Parameter Optimization ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Tensile Shear Strength ◽  
Tensile Shear ◽  
Resistance Spot

Resistance Spot Welding (RSW) is processed by using aluminum alloy used in the automotive industry. The difficulty of RSW parameter setting leads to inconsistent quality between welds. The important RSW parameters are the welding current, electrode force, and welding time. An additional RSW parameter, that is, the electrical resistance of the aluminum alloy, which varies depending on the thickness of the material, is considered to be a necessary parameter. The parameters applied to the RSW process, with aluminum alloy, are sensitive to exact measurement. Parameter prediction by the use of an artificial neural network (ANN) as a tool in finding the parameter optimization was investigated. The ANN was designed and tested for predictive weld quality by using the input and output data in parameters and tensile shear strength of the aluminum alloy, respectively. The results of the tensile shear strength testing and the estimated parameter optimization are applied to the RSW process. The achieved results of the tensile shear strength output were mean squared error (MSE) and accuracy equal to 0.054 and 95%, respectively. This indicates that that the application of the ANN in welding machine control is highly successful in setting the welding parameters.

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