Influence of resistance spot welding process parameters on dissimilar austenitic and duplex stainless steel welded joints

2020 ◽  
pp. 095440892093352
Author(s):  
Vignesh Krishnan ◽  
Elayaperumal Ayyasamy ◽  
Velmurugan Paramasivam
Keyword(s):  
Stainless Steel ◽  
Duplex Stainless Steel ◽  
Shear Fracture ◽  
Welding Current ◽  
Fracture Load ◽  
Welding Parameters ◽  
Shear Load ◽  
Tensile Shear ◽  
Aisi 316 ◽  
Aisi 316 L

This paper examines the impact of welding parameters on tensile shear fracture load, nugget geometry and microstructure of resistance spot welds (RSW) of austenitic stainless steel AISI 316 L and duplex stainless steel 2205 under lap shear loading condition. The macroscopic examination resulted that many of the nugget lengths were nearer to and higher than the AWS recommended value 4√t and failed at higher tensile shear load. Nugget height for DSS 2205 side was higher in comparison with AISI 316 L due to higher thermal conductivity of duplex stainless steel. Three welding parameters mainly welding current of 9 kA, heating cycle of 9 and electrode tip diameter of 6 mm were discovered as most effectual parameters on the tensile shear load and microstructure of weldments. Heterogeneous hardness was observed in the fusion zone due to the transition of equiaxed to columnar grains takes place in the both sides of nugget edge. DSS HAZ nearby BM observed higher hardness and ASS HAZ nearby BM reported lower hardness. WMZ Microstructure confirmed that thickness of austenite layers increased with heat input. Also, an unmixed zone in the microstructure identified as HAZ which contains delta ferrite. Scanning Electron Microscope (SEM) images in the nugget zone for different welding parameters confirmed that Intra-Granular Austenite (IGA) highly developed at higher welding current. SEM fractrograph for the tensile sheared specimens at higher and lower heat input confirmed the ductile type fracture even failed at Inter-Facial (IF) mode. Nugget area and nugget hardness were positively correlated with Tensile Shear Fracture Load (TSFL).

AN EMPIRICAL RELATIONSHIP FOR ESTIMATING METALLURGICAL AND MECHANICAL BEHAVIOR OF RESISTANCE SPOT WELDED DP800 STEEL JOINTS

2019 ◽  
Vol 14 (2) ◽  
Author(s):  
Rajarajan C ◽  
Sivaraj P ◽  
Balasubramanian V
Keyword(s):  
Shear Fracture ◽  
Empirical Relationship ◽  
Testing Machine ◽  
Welding Current ◽  
Fracture Load ◽  
Peak Hardness ◽  
Tensile Shear ◽  
Nugget Zone ◽  
Resistance Spot ◽  
Increase With Increase

Similar joints of DP800 (Dual Phase) steel in lap joint configuration were fabricated using resistance spot welding (RSW) process. The process parameters were optimized using DOE (design of experiments) and the welds joints were fabricated using the obtained DOE matrix. The tensile shear fracture load (TSFL) of joints was evaluated using universal testing machine. Microhardness variations across the weld cross-section was recorded using Vickers’s microhardness tester. Microstructural features were analyzed using optical microscopy (OM) and scanning electron microscopy (SEM). From this investigation, it is understood that increase in welding current increases the nugget zone size and it led to increasing the degrease of softening in the HAZ. The tensile shear strength is found to increase with increase in welding current up to a certain limit and then it decreases. The microhardness profile shows a peak hardness in nugget zone and the hardness is lower in the HAZ. The softening of HAZ is mainly attributed to inter-critical heating during welding.

Optimization of Parameters and Research on Joint Microstructure of Resistance Spot Welding for 316 Stainless Steel

2013 ◽  
Vol 652-654 ◽  
pp. 2326-2329 ◽  
Author(s):  
Hui Liu ◽  
Xue Dong Xu ◽  
Xiao Qing Zhang
Keyword(s):  
Stainless Steel ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Welding Current ◽  
Shear Load ◽  
Welding Time ◽  
Tensile Shear ◽  
316 Stainless Steel ◽  
Resistance Spot ◽  
Electrode Force

The experimental investigations on resistance spot welding are presented for 316 stainless steel. The influence of spot welding parameters (welding time, electrode force and welding current) on the tensile shear load and the diameter of nugget have been researched, based on an orthogonal test and analysis method. The results show that welding current has significant influence on the tensile shear load and diameter of nugget, and then is electrode force, welding time in turn. The optimum parameters are as follows: welding time is 5 cycles, electrode force is 3.5KN and welding current is 5.5KA. And the maximum tensile shear force of joint is up to 13.55KN.

scholarly journals Investigation into the Effect of RFSSW Parameters on Tensile Shear Fracture Load of 7075-T6 Alclad Aluminium Alloy Joints

Materials ◽  
2021 ◽  
Vol 14 (12) ◽  
pp. 3397
Author(s):  
Andrzej Kubit ◽  
Tomasz Trzepieciński ◽  
Elżbieta Gadalińska ◽  
Ján Slota ◽  
Wojciech Bochnowski
Keyword(s):  
Aluminium Alloy ◽  
Shear Fracture ◽  
Load Capacity ◽  
Fracture Load ◽  
Tensile Fracture ◽  
Welding Parameters ◽  
Tensile Shear ◽  
Optimal Amount ◽  
Average Value ◽  
Type Fracture

The aim of the investigations was to determine the effect of parameters of refill friction stir spot welding (RFSSW) on the fracture load and failure mechanisms of the resulting joint. RFSSW joints were made in 7075-T6 Alclad aluminium alloy sheets using different welding parameters. The load capacity of joints was determined under tensile/shear loadings. Finite element-based numerical simulations of the joint-loading process were carried out, taking into account the variability of elasto-plastic properties of weld material through the joint cross-section. The influence of welding parameters on selected phenomena occurring during the destruction of the joint is presented. The considerations were supported by a fractographic analysis based on SEM images of fractures. It was found that there is a certain optimal amount of heat generated, which is necessary to produce the correct joint in terms of its load capacity. This value should not be exceeded, because it leads to weakening of the base material and thus to a reduction in the strength of the joint. Samples subjected to uniaxial tensile shear load showed three types of failure mode (tensile fracture, shear fracture, plug type fracture) depending on the tool rotational speed and duration of welding. Prediction of the fracture mode using FE-based numerical modelling was consistent with the experimental results. The samples that were damaged due to the tensile fracture of the lower sheet revealed a load capacity (LC) of 5.76 KN. The average value of LC for the shear fracture failure mechanism was 5.24 kN. The average value of the LC for plug-type fracture mode was 5.02 kN. It was found that there is an optimal amount of heat generated, which is necessary to produce the correct joint in terms of its LC. Excessive overheating of the joint leads to a weakening of the base metal and thus a reduction in the strength of the joint. Measurements of residual stresses along the axis specimens showed the presence of stresses with a certain constant value for the welded area on the side of the 1.6 mm thick plate.

scholarly journals Comparison between PCA analysis and Grey based Taguchi analysis of TIG welding process parameters on Duplex stainless steel

2021 ◽  
pp. 67-74
Author(s):  
Sandip Mondal ◽  
Goutam Nandi ◽  
Pradip Kumar Pal
Keyword(s):  
Stainless Steel ◽  
Duplex Stainless Steel ◽  
Process Parameters ◽  
Gas Flow ◽  
Welding Process ◽  
Principal Component ◽  
Welding Current ◽  
Tig Welding ◽  
Welding Parameters ◽  
Welding Quality

Tungsten inert gas (TIG) welding on Duplex stainless steel (DSS) is more easy, comfortable and useful, if the process is precisely understood and controlled through development of the science & technology. TIG welding on DSS has been performed with the help of specific controlled welding process parameters. Welding quality has been strongly depended on these process parameters. In this study, some valuable welding parameters are chosen. These are welding current, shielding gas flow rate and speed of welding. These process parameters of TIG welding for ASTM/UNS 2205 DSS welds are optimized by using Principal Component Analysis (PCA) method and Grey based Taguchi’s L9 Orthogonal array (OA) experimental plan with the conception of signal to noise ratio (N/S). After that, compression results of above mentioned two analyses of TIG welding process parameters have been calculated. The quality of the TIG welding on DSS has been evaluated in term of ultimate tensile strength, yield strength and percentage of elongation. Compression results of both analyses indicate application feasibility for continuous improvement of welding quality on DSS in different components of chemical, oil and gas industries.

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.

Mechanical properties of dissimilar Ti-Al resistance spot welds

2020 ◽  
Vol 62 (6) ◽  
pp. 597-602
Author(s):  
Rukiye Ertan
Keyword(s):  
Mechanical Properties ◽  
Welding Current ◽  
Alloy Sheet ◽  
Welding Parameters ◽  
Shear Load ◽  
Tensile Shear ◽  
Resistance Spot ◽  
Resistance Spot Welds ◽  
Nugget Formation ◽  
Spot Welded

AbstractIn this study, the mechanical behavior of titanium (ASTM Grade 2) alloy sheet, resistance spot welded with 5754 aluminum alloy, was investigated with respect to nugget formation and mechanical properties. The welding operations were performed using resistance spot welding at various welding currents (10, 12.5 and 15 kA), welding times (10, 15 and 20 cycles) and electrode forces (5, 10 and 15 kN). The weld nugget diameter and nugget center height, hardness, and tensile-shear test results of the welded samples were examined, and the mechanical properties were compared. As a result of the tests, it was seen that the welding parameters have a significant effect on the mechanical properties of the titaniumaluminum alloy welding joints. The tensile-shear load of the resistance spot welded joints increased as the welding current increased, and welding time increased for 15 cycles. On the other hand, when the electrode force increased, the tensile-shear load decreased markedly.

Resistance Spot Welding between Mild Steel and Stainless Steel

2014 ◽  
Vol 675-677 ◽  
pp. 23-26
Author(s):  
Nan Nan Wang ◽  
Ran Feng Qiu ◽  
Wei Jian Peng ◽  
Hong Xin Shi
Keyword(s):  
Stainless Steel ◽  
Shear Strength ◽  
Mild Steel ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Welding Current ◽  
Welding Parameters ◽  
Tensile Shear Strength ◽  
Tensile Shear ◽  
Resistance Spot

Mild steel Q235 and stainless steel SUS304 were welded using resistance spot welding with an interlayer of Ni. The mechanical properties of the joint were examined, the effects of welding parameters on the nugget size and tensile shear strength were investigated. Both the tensile shear strength and nugget diameter increased with the increasing of welding current and welding time, whereas they decreased with the increasing of electrode pressure. The results indicate that the tensile shear strength of joint welded by resistance spot welding with a Ni interplayer is higher in comparison with that obtained by conventional resistance spot weling.

scholarly journals Influence of electrode tip diameter on metallurgical and mechanical aspects of spot welded duplex stainless steel

2020 ◽  
Vol 39 (1) ◽  
pp. 317-327
Author(s):  
Vivek D. Kalyankar ◽  
Gautam P. Chudasama
Keyword(s):  
Stainless Steel ◽  
Duplex Stainless Steel ◽  
Mechanical Performance ◽  
Welding Current ◽  
Thick Sheet ◽  
Automotive Body ◽  
Nugget Diameter ◽  
Feasible Range ◽  
Research Outcome ◽  
Spot Welded

AbstractIn this article, the influence of electrode tip diameter is investigated for spot welded duplex stainless steel (DSS). Electrode tip diameter and welding current are considered as the major influencing parameters and their values are varied within the feasible range, suitable for 0.8 mm thick sheet, whereas other important parameters such as welding time and electrode force are kept constant. DSS with the chosen thickness range is now becoming a useful material in automotive body-in-white applications and in future it will become one of the key materials replacing the existing materials and hence research outcome of the present work may be beneficial from application view point. In this work, the spot welding quality is inspected through metallurgical aspects (microstructure and microhardness), physical aspects (nugget diameter and electrode indentation), mechanical performance (tensile shear strength [TSS]) and failure mode. The obtained result shows that smaller electrode tip diameter limits nugget diameter due to expulsion phenomena and increases electrode indentation due to higher current intensity. TSS decreases with increase in electrode tip diameter for the same welding current but maximum TSS obtained for particular electrode tip diameter increases with increase in electrode tip diameter up to a specific limit and then it remains constant.

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