Numerical Analysis of Transport Phenomena in Resistance Spot Welding Process

2011 ◽  
Vol 133 (3) ◽  
Author(s):  
YongBing Li ◽  
ZhongQin Lin ◽  
Qi Shen ◽  
XinMin Lai
Keyword(s):  
Mass Transport ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Welding Process ◽  
Weld Nugget ◽  
Temperature Dependent ◽  
Resistance Spot ◽  
Nugget Formation ◽  
Thermal Fluid Flow ◽  
Transport Laws

Resistance spot welding (RSW) is a very complicated process involving electromagnetic, thermal, fluid flow, mechanical, and metallurgical variables. Since weld nugget area is closed and unobservable using experimental means, numerical methods are generally used to reveal the nugget formation mechanism. Traditional RSW models focus on the electrothermal behaviors in the nugget and do not have the ability to model mass transport caused by induced magnetic forces in the molten nugget. In this paper, a multiphysics model, which comprehensively considers the coupling of electric, magnetic, thermal, and flow fields during RSW, temperature-dependent physical properties, and phase transformation, is used to investigate the heat and mass transport laws in the weld nugget and to reveal the interaction of the heat and mass transports and their evolutions. Results showed that strong and complicated mass transport appears in the weld nugget and substantially changed the heat transport laws and, therefore, would be able to substantially affect the hardening, segregation, and residual stress of the weld. Compared with the traditional models which could not consider the mass transport, the multiphysics model proposed in this paper could simulate the RSW process with higher accuracy and more realities.

Numerical Analysis of Transport Phenomena in Resistance Spot Welding Process

2009 ◽  
Author(s):  
Yong Bing Li ◽  
Zhong Qin Lin ◽  
Li Li ◽  
Guan Long Chen
Keyword(s):  
Mass Transport ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Welding Process ◽  
Weld Nugget ◽  
Resistance Spot ◽  
Nugget Formation ◽  
Electro Magnetic ◽  
Physics Model ◽  
Thermal Fluid Flow

Resistance Spot Welding (RSW) is a very complicated process involving electro-magnetic, thermal, fluid flow, mechanical and metallurgical variables. Since weld nugget area is close and unobservable with experimental means, numerical methods are mainly used to reveal the nugget formation mechanism. Traditional RSW models focus on the electro-thermal behaviors in the nugget, and do not have the ability to model mass transport caused by induced magnetic forces in the molten nugget. In this paper, a multi-physics model, which comprehensively considers the coupling of electric, magnetic, thermal and flow fields during RSW, temperature-dependent physical properties and phase transformation, is used to investigate the heat and mass transport laws in the weld nugget and to reveal the interaction of the heat and mass transports. Results show that the heat transport behaviors in the weld nugget, the profile of the nugget, and the thermal field evolution are significantly changed when the mass transport is considered. At the same time, a good agreement is also found between experimental and numerically calculated nugget sizes. As a result, when predicting crystal growth process, the effects of the mass transport should be considered in order to obtain a more accurate prediction results.

A Simplified Transient Thermal Analysis of Resistance Spot Welding Process

2010 ◽  
Vol 154-155 ◽  
pp. 443-446
Author(s):  
Zhi Gang Hou ◽  
Jun Zhao ◽  
Li Qiang Xu ◽  
Zhong Guo
Keyword(s):  
Resistance Spot Welding ◽  
Spot Welding ◽  
Complex Structure ◽  
Welding Process ◽  
Temperature Dependent ◽  
Resistance Spot ◽  
Whole Process ◽  
History Of ◽  
Transient Thermal

In order to theoretically simulate the welding process of complex structure with large quantities of welding spots, a simplified method for analyzing a single spot welding should be developed firstly. In this paper, a 2D axisymmetric model of thermoelectric Finite Element Method (FEM) is developed to analyze the transient thermal behavior of Resistance Spot Welding (RSW) process using ANSYS. The determination of the contact resistance at the faying surface is moderately simplified to reduce the calculating time, while the temperature dependent material properties, phase change and convectional boundary conditions are taken into account for the improvement of the calculated accuracy. The thermal history of the whole process and temperature distributions for any position in the weldment is obtained through the analysis. The model can also predict the weld nugget size and the width of the Heat Affected Zone (HAZ).

scholarly journals Effect of Zinc Coating on Delay Nugget Formation in Dissimilar DP600 - AISI304 Welded Joints Obtained by the Resistance Spot Welding Process

2021 ◽  
Author(s):  
Mercedes Pérez de la Parte ◽  
Alejandro Espinel Hernández ◽  
Mario César Sánchez Orozco ◽  
Angel Sánchez Roca ◽  
Emilio Jiménez Macias ◽  
...  
Keyword(s):  
Welded Joints ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Zinc Coating ◽  
Welding Process ◽  
Dynamic Resistance ◽  
Time Duration ◽  
Resistance Spot ◽  
Nugget Formation ◽  
Resistance Curves

Abstract This paper researches the effect of zinc coating of galvanized DP600 steel on the dynamic resistance and the delayed nugget formation of dissimilar DP600 - AISI304 welded joints, obtained with resistance spot welding process (RSW). The RSW evaluations consisted of determining, from the dynamic resistance curves, the time involved in the different stages of the process, particularly the beginning of nugget formation. The experimental results showed that, from the dynamic resistance curves, it is possible to identify 8 distinct stages during the welding of galvanized DP600 steel and AISI304 stainless steel. In the case of the welding of uncoated DP600 steel with AISI304, only 6 stages are identified (except for stages 2 and 3), which are directly related to the heating, softening and melting of the galvanic coating. The energy used in stages 2 and 3, causes a delay in the beginning of nugget formation for welded joints obtained with galvanized DP600 steel compared to uncoated DP600 - AISI304 welded joints, reaching values between 37.28 ms and 52.29 ms for the welding conditions analyzed. Monitoring the time duration of stages 2 and 3, as defined from the analysis of the dynamic resistance curves, could be used as a tool to predict the beginning of nugget formation in the welding of galvanized steels, to avoid undesirable phenomena such as expulsion and to guarantee the quality of the welded joints.

Numerical simulation of weld nugget in resistance spot welding process

2020 ◽  
Vol 27 ◽  
pp. 2958-2963
Author(s):  
Abhishek Kumar ◽  
Sikta Panda ◽  
Gaurab Kumar Ghosh ◽  
Ritesh Kumar Patel
Keyword(s):  
Numerical Simulation ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Welding Process ◽  
Weld Nugget ◽  
Resistance Spot

Weld nugget formation in resistance spot welding of new lightweight sandwich material

2015 ◽  
Vol 80 (5-8) ◽  
pp. 1137-1147 ◽  
Author(s):  
J. Sagüés Tanco ◽  
C. V. Nielsen ◽  
A. Chergui ◽  
W. Zhang ◽  
N. Bay
Keyword(s):  
Resistance Spot Welding ◽  
Spot Welding ◽  
Weld Nugget ◽  
Resistance Spot ◽  
Nugget Formation

Numerical Study of Thermal Modeling of Resistance Spot Welding Utilizing Coupled Thermal-Electrical-Mechanical Analysis

1999 ◽  
Author(s):  
Lijun Xu ◽  
Jamil A. Khan ◽  
Yuh-Jin Chao ◽  
Kirkland Broach
Keyword(s):  
Resistance Spot Welding ◽  
Spot Welding ◽  
Numerical Study ◽  
Mechanical Analysis ◽  
Convective Transport ◽  
Temperature Dependent ◽  
Resistance Spot ◽  
Proposed Model ◽  
Nugget Formation ◽  
Surface Contact Area

Abstract This paper successfully proposes a novel model to predict nugget development during resistance spot welding (RSW) of binary Al-alloys. The model employs a coupled thermal-electrical-mechanical analysis, and also accounts for phase change and convective transport in weld pool. Faying surface contact area and its pressure distribution are simulated from coupled thermal-mechanical model using a finite element method. Temperature dependent thermal, electrical and mechanical properties are used. The proposed model can successfully calculate most of the RSW response in term of nugget diameter and thickness, the extent of heat affected zone, etc. The calculated nugget shape based on the thermal model agrees well with the experimental data. Convection effect due to the interactions between phases in the porous mushy zone and the buoyancy force arising from the temperature difference is determined to be not significant for the weld-nugget formation. The proposed model can be used to optimize RSW process parameters for industrial welding.

Study on Nugget Growth in Resistance Spot Welding of Thin Aluminum A1100 Using Welding Simulation

2018 ◽  
Vol 929 ◽  
pp. 191-199
Author(s):  
Ario Sunar Baskoro ◽  
Andreas Edyanto ◽  
Muhammad Azwar Amat ◽  
Hakam Muzaki
Keyword(s):  
Weld Joint ◽  
Cycle Time ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Welding Process ◽  
Metal Plate ◽  
Weld Nugget ◽  
Welding Time ◽  
Resistance Spot ◽  
Nugget Growth

Resistance spot welding (RSW), generally which is one of the most often used to joint metal plate in the automotive and aviation industries. RSW welding process involves electrical, thermal mechanical, metallurgy, and complex surface phenomenon. Unlike the other welding processes, weld joint formation in RSW process occurs very quick (in milli-seconds) and took place between the workpieces overlap each other. Welding simulation allows visual examination of the weld joint without having to perform an expensive experiment. Weld nugget size is the most important parameter in determining the mechanical behavior of welded joints in RSW process. The quality and strength of the weld joint in RSW process is predominantly determined by the shape and size of the weld nugget. Simulation modeling of RSW process performed using ANSYS Parametric Design Language (APDL) module based on the finite element method (FEM), embedded in ANSYS Workbench. Electrical and transient-thermal interaction was developed to study the weld nugget growth on resistance spot welding of aluminum A1100 metal plate with a thickness of 0.4 mm respectively. Weld nugget diameter can be well predicted by using this simulation model from the temperature distribution during the welding process. Welding is performed by varying the weld current (1 kA and 2 kA) and the welding time for each electric current, which are start from 0.5, 1.0, and 1.5 cycle time. Nugget diameter for each of the welding parameters from the simulation modelling were 4,276 mm, 4,372 mm, 4,668 mm, 5,616 mm and 5,896 mm. Weld expulsion occurred for the specimen with welding current 2 kA and welding time 1.5 cycle time, characterized by the decreasing of the tensile-shear strength of the specimen.

scholarly journals Effect of Double Pulse Resistance Spot Welding Process on 15B22 Hot Stamped Boron Steel

Metals ◽  
2020 ◽  
Vol 10 (10) ◽  
pp. 1279
Author(s):  
Hwa-Teng Lee ◽  
Yuan-Chih Chang
Keyword(s):  
Heat Input ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Welding Process ◽  
Double Pulse ◽  
Weld Nugget ◽  
Boron Steel ◽  
Welding Parameters ◽  
Tensile Shear ◽  
Resistance Spot

Double pulse resistance spot welding process by applying a second step welding current is a new pathway to alter the mechanical properties for advanced high strength steels. Herein, the resistance spot welding (RSW) of hot stamped boron steel 15B22 by one-step and two-step welding with different welding currents is investigated. The results of the tensile–shear test, size of the weld nugget, hardness distribution, microstructure, and failure mode of different welding parameters are analyzed. The weldment of the two-step RSW with a higher heat input exhibits a lower tensile–shear load and lower fracture energy when the size of the weld nugget is large. The microstructural study reveals the appearance of a partially melted zone and sub-critical heat affected zone in the weldment where the fracture readily occurred. Thus, the two-step RSW process weakens the strength of the sample, which is attributed to the partial softening in the weldment due to the higher heat input.

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