A novel expulsion control strategy with abnormal condition adaptability for resistance spot welding

2021 ◽  
pp. 1-27
Author(s):  
Yan Shen ◽  
Yu-Jun Xia ◽  
Huan Li ◽  
Lang Zhou ◽  
Hai-Tao Pan ◽  
...  
Keyword(s):  
Control Strategy ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Welding Current ◽  
Weld Nugget ◽  
Size Difference ◽  
Welding Parameters ◽  
Low Carbon ◽  
Resistance Spot ◽  
Abnormal Condition

Abstract Welding expulsion is a common problem in Resistance Spot Welding (RSW) process, which severely impacts weld quality and surrounding facilities. Existing expulsion control strategies are ineffective for complex and changeable welding conditions. This article studied the growth relationship between weld nugget and corona bond under two abnormal conditions: edge proximity (EP) and initial sheet gaps (IG). It is testified that expulsion would occur when the nugget size exceeds the corona bond size under EP and IG conditions. Reducing the welding current before the expulsion time can increase the size difference between the corona bond and the weld nugget, thereby delay and even eliminate the occurrence of expulsion. In this way, a novel online expulsion control strategy, named short-time current regulation (STCR), is proposed through expulsion moment analysis of historical weld data. The effect of the new control strategy is verified with workpieces ranging from low carbon steel to ultra-high strength steel. Experimental results showed that STCR can effectively reduce the amount of expelled metal, decrease the indentation depth and increase the nugget diameter. The method not only works well under one specific abnormal condition, but also adapts to the transition between different welding conditions. This novel expulsion control strategy can help achieve expulsion-free RSW process in mass production without frequent manual offline optimization of welding parameters.

scholarly journals Optimization on Spot Weld Parameters in Resistance Spot Welding Process on AISI 304

2021 ◽  
Vol 11 (3) ◽  
pp. 181-185
Author(s):  
Amit Hazari ◽  
Rith Saha ◽  
Bidisha Ghosh ◽  
Debraj Sengupta ◽  
Sayan Sarkar ◽  
...  
Keyword(s):  
Resistance Spot Welding ◽  
Spot Welding ◽  
Welding Process ◽  
Welding Current ◽  
Electrical Current ◽  
Industrial Applications ◽  
Spot Weld ◽  
Welding Parameters ◽  
Resistance Spot ◽  
Weld Time

The spot welding procedure is used in a variety of industrial applications. The most critical elements influencing welding quality, productivity, and cost are the spot welding parameters. This research examines the effect of welding factors such as welding current and welding time on the strength of various welding joint designs. Resistance spot welding (RSW) is used in the automotive industry for manufacturing. This research focused on the optimization of process parameters for resistance spot welding (RSW), as well as the tensile testing and spot weld diameter. The goals of this analysis are to comprehend the physics of the process and to demonstrate the effect of electrical current, weld time, and material type on the resistance spot welding process.

Effect of Welding Current and Welding Time for Micro Resistance Spot Welding on Dissimilar Thin Thickness Materials of Al 1100 and KS 5 Spring Steel

2016 ◽  
Vol 842 ◽  
pp. 120-124 ◽  
Author(s):  
Ario Sunar Baskoro ◽  
Hakam Muzakki ◽  
Winarto
Keyword(s):  
Cycle Time ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Welding Current ◽  
Spring Steel ◽  
Welding Parameters ◽  
Shear Load ◽  
Welding Time ◽  
Resistance Spot ◽  
Fracture Area

In the dissimilar materials and dissimilar thin thickness sheets joining, welding current and welding time parameters of resistance spot welding (RSW) effect weld ability. RSW used for joining thin plate less than 1000 μm is called micro-resistance spot welding (μRSW). The objective of this article is to study the effect of welding current and welding time to the joining dissimilar thin thickness materials and the microstructure of a weld joint. The thickness of Al 1100 is 400 μm, and KS 5 Spring Steel is 200 μm. Welding parameters are Cycle Time 0.5, 1, 1.5, Welding Current 1kA and 2 kA, and holding time 10 second. Welding current 1kA, Cycle time of 0.5 produce maximum shear load of 227.4 N and fracture area of 6.644 mm2. Welding current 2 kA, cycle time of 1.5 affect maximum load of 222.7 N and fracture area of 10.559 mm2. Welding parameters lead to the majority fracture on aluminum material. The welding current and cycle time do not significantly affect maximum shear load and fracture area.

Resistance Spot Welding between Copper Coated Steel and Aluminum Alloy

2014 ◽  
Vol 675-677 ◽  
pp. 19-22 ◽  
Author(s):  
Li Hu Cui ◽  
Ran Feng Qiu ◽  
Hong Xin Shi ◽  
Yao Min Zhu
Keyword(s):  
Aluminum Alloy ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Welding Current ◽  
Middle Layer ◽  
Welding Parameters ◽  
Coated Steel ◽  
Resistance Spot ◽  
Nugget Diameter ◽  
Electrode Force

Aluminum alloy A6061 and copper coated steel was welded by resistance spot welding with. The mechanical properties of the joint were investigated; the effects of welding parameters on nugget diameter and tensile shear load of the joints were discussed. The results show that the joint strength and nugget diameter increases with the increase of welding current and welding time and decreases with the increase of electrode force. As a result, copper plating as the middle layer of resistance spot welding is suitable for welding of aluminum alloy/steel.

scholarly journals Optimization of Resistance Spot Welding (RSW) Parameters by using Taguchi Method

2020 ◽  
Vol 9 (3) ◽  
pp. 2795-2800
Keyword(s):  
Shear Strength ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Welding Current ◽  
Welding Parameters ◽  
Welding Time ◽  
Tensile Shear Strength ◽  
Tensile Shear ◽  
Resistance Spot ◽  
Electrode Force

This study was intended to optimize the resistance Spot Welding Parameters (RSW) of sheet metals joints. The variation parameters selected were electrode force, welding current and welding time of 1.2 mm thickness low carbon steel. The settings of process parameters were conducted according to the L9 Taguchi orthogonal array in randomized way. The optimum process parameter was then obtained by using signal to noise ratio and analyzed further on the significant level by using Analysis of Variance (ANOVA). The developed response has been found well fitted and can be effectively used for tensile shear strength prediction. The optimum parameters achieved were electrode force (2.3 kN), welding time (10 cycles) and welding current (8 kA). Based on the ANOVA, it was found that the electrode force is a vital parameter in controlling the tensile shear strength as compared to welding time and welding current.

scholarly journals Resistance spot welding of dissimilar alloys 1008 low carbon steel5052 aluminum alloy

2018 ◽  
Vol 8 (02) ◽  
Author(s):  
Mohammad Jameel Zedan ◽  
Qasim M. Doos
Keyword(s):  
Aluminum Alloy ◽  
Carbon Steel ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Low Carbon Steel ◽  
Welding Current ◽  
Intermetallic Compound Layer ◽  
Low Carbon ◽  
Resistance Spot ◽  
Dissimilar Alloys

The resistance spot welding is adopted to joint dissimilar alloys such as aluminum alloy 5052, and low carbon steel alloy 1008. In this work, the electrodes force 2100-2700 N, the welding current 7.5-10.5 KA, and welding time 10-20 cycle have been used. The relationships between the three parameters have been studied. The maximum tensile shear load of the aluminum alloy 5052-low carbon steel 1008 joint has been found equal to 2860 N for weld nugget diameter of 9 mm. The intermetallic compound layer (IMC) with 2-8 μm thickness with tongue-like has been appeared adjacent to the 1008 low carbon steel side, whereas a needle-shaped IMC layer adjacent to the aluminum alloy 5052 side

scholarly journals Connection Status Research of the Resistance Spot Welding Joint Based on a Rectangular Terminal Electrode

Metals ◽  
2019 ◽  
Vol 9 (6) ◽  
pp. 659
Author(s):  
Xiaoqi Zhang ◽  
Lingbo Wei ◽  
Guocheng Xu ◽  
Chunsheng Wang
Keyword(s):  
Resistance Spot Welding ◽  
Spot Welding ◽  
Process Analysis ◽  
Welding Process ◽  
Welding Current ◽  
Welding Parameters ◽  
Current Time ◽  
Axis Direction ◽  
Resistance Spot ◽  
Welding Pressure

Rectangular terminal electrode is adopted in this research to conduct a resistance spot welding (RSW) process on stainless steel plate. The connection status of RSW joints under different welding current, time, and pressure were studied, and revealed how the rectangular terminal electrode shape and its dimensions influence the RSW joint dimensions. The process analysis results showed that the RSW nuggets welded with rectangular terminal electrode are normally elliptical in shape, and the dimensions of the long axis direction and the short axis direction have a certain proportion. As the welding current increases, the nuggets dimensions in long direction increase first and then decrease, and the internal grain structure also varies. As the welding time increases, the nugget size in long direction increase first and then steady and rarely splash occurs. As the welding pressure increase, the nugget dimensions in long direction increase first and then decrease, and the splash easily occurs under large welding pressure. However, when the welding pressure is too small, the unique adjacent double fusion nugget formed. By adopting proper welding parameters, the nugget size and quality can be controlled. This provides an important basis for the application of rectangular terminal electrode in RSW welding process.

Optimization of Parameters and Research on Joint Microstructure of Resistance Spot Welding of 201 Stainless Steel

2011 ◽  
Vol 418-420 ◽  
pp. 1359-1363 ◽  
Author(s):  
Hui Liu ◽  
Hai Dong Wang ◽  
Xiao Qing Zhang ◽  
Cai Wen Li
Keyword(s):  
Stainless Steel ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Great Influence ◽  
Welding Current ◽  
Welding Parameters ◽  
Welding Time ◽  
Tensile Shear ◽  
Resistance Spot ◽  
Electrode Force

The experimental investigations on resistance spot welding of 201 stainless steel are presented. Experiments are carried out to study the influence of spot welding parameters (electrode force, welding current and welding time) on the tensile shear load and the diameter of nugget, based on an orthogonal test and analysis method. The optimum parameters are as follows: electrode force is 3600N, welding current is 6400A and welding time is 8 cycles. The maximum tensile shear force is up to 8920N.The microstructure of spot weld is columnar crystals in the nugget and equiaxed grains around periphery induced by non-equilibrium freezing. And the heat input has great influence on the welding defects which can cause joint quality degradation.

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.

Optimization of Welding Parameters for Small-Scale Resistance Spot Welding of Zirconium Alloys

2019 ◽  
Vol 970 ◽  
pp. 145-152 ◽  
Author(s):  
Mikhail S. Slobodyan ◽  
Aleksey S. Kiselev
Keyword(s):  
Tensile Strength ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Stable State ◽  
Welding Current ◽  
Zirconium Alloys ◽  
Metal Structure ◽  
Welding Parameters ◽  
Small Scale ◽  
Resistance Spot

This paper presents the results of optimization of parameters for resistance spot welding of parts made of E110 zirconium alloy with a thickness of 0.25 + 0.25 mm. Its purpose was to determine the influence of welding current profiles on nugget metal structure and mechanical properties of welds. The highest tensile strength comparable with base metal (380...440 MPa) was observed when the ratio of integral heat input to current pulse duration was about two. Formation of martensitic structure and coarsening of nugget metal was observed with larger ratios. A proper fusion zone was not formed with lower ratios. Annealing of welded joints at a pressure of ~ 10–4 Pa and a temperature of 580 °C for one hour was necessary to reduce residual stresses and transformation of metastable martensitic phase to a more stable state. This reduced microhardness of nugget metal by 30...35% and increased tensile strength of welds. It was also possible to increase tensile strength and reduce dispersion of its values by increasing duration of current down slope after formation of a nugget. An increase in duration from 1 to 14 ms caused rise in tensile strength by ~ 18% and dispersion of its values by ~ 3%.

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