scholarly journals Monitoring of resistance spot welding process

2021 ◽  
Vol 5 (2) ◽  
Author(s):  
Yaroslav Sovetchenko ◽  
Dmytro Vdovychenko ◽  
Ivan Vdovychenko ◽  
Yevgenia Chvertko ◽  
Igor Skachkov ◽  
...  
Keyword(s):  
Resistance Spot Welding ◽  
Spot Welding ◽  
Welding Process ◽  
Evaluation Process ◽  
The State ◽  
Welding Parameters ◽  
High Productivity ◽  
Resistance Spot ◽  
Level Of Automation ◽  
High Level

Resistance spot welding is a process with high productivity and high level of automation. This rises a number of tasks related to development of quality evaluation and process monitoring systems operating in real-time mode which would allow to detect non-compliant joints during the process run of shortly after it is finished. The more complex task is to make such system as much universal as possible, consisting of relatively simple equipment and with a possibility of full automation of evaluation process. Research was focused on electrical welding parameters which determine the thermal cycle of the welding process as well as the state of metal in the welding zone and its plasticity. Experiments were performed for work pieces with different pre-welding state of surface. Developed method also allows to monitor the state of working surfaces of electrodes and to detect splashes with a relatively high accuracy.

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.

Single-Side Resistance Spot Welding Process for Joining Pipes and Sheets

2013 ◽  
Vol 7 (1) ◽  
pp. 114-119 ◽  
Author(s):  
Hitomi Nishibata ◽  
◽  
Shota Kikuchi ◽  
Manabu Fukumoto ◽  
Masato Uchihara
Keyword(s):  
Resistance Spot Welding ◽  
Spot Welding ◽  
Numerical Study ◽  
Welding Process ◽  
Welding Parameters ◽  
Resistance Spot ◽  
Welding Technology ◽  
Single Side ◽  
Side Resistance ◽  
Nugget Growth

This paper describes a Single-Side resistance Spot Welding (SSSW) process which is expected to be a productive welding technology for the joining of stamped sheet panels to hollow parts for auto bodies. To obtain guidelines for making a sound weld with the SSSW process, the effects of welding parameters and the alignment of specimens on nugget growth are investigated experimentally. In addition, a numerical study is carried out to discuss the mechanism of nugget growth in the SSSW process.

Multi Response Optimization of Spot Welding Process Parameters by Taguchi Method

2020 ◽  
Vol 12 (1) ◽  
Author(s):  
S.P. Sundar Singh Sivam ◽  
A. Thirugnanam ◽  
K. Saravanan ◽  
D. Kumaran ◽  
M. Suresh
Keyword(s):  
Electrical Resistance ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Weld Zone ◽  
Welding Process ◽  
Class Ii ◽  
Welding Parameter ◽  
Welding Parameters ◽  
Resistance Spot ◽  
Steel Sheets

Electrode deterioration by deformation and chemical reaction during resistance spot welding of steel sheets confirming to AISI1020 is an issue for class II electrode. In view of this, the present study carried out the impacts of squeeze, weld, current and pressure on the nugget diameter, height, force and waviness of welding joint in electrical resistance spot welding of 0.8mm and 1.5 mm thickness of steel sheets with class II electrode to achieve the benefits of cost saving and quality products. A timer and current controlled electrical resistance spot welding machine having 120 kVA capacities were used. During welding process, current periods of 5, 10, 15, 20 and 25 were selected and it was adjusted by increasing from 8 to 10 kA. The optimum welding parameter for multi objectives was obtained using multi signal to noise ratio and the significant level of the welding parameters was further analysed by analysis of variance for all responses. Based on the confirmation test results, it is found out that the developed model can be effectively used to predict the size of weld zone which can improve the welding quality and performance in GRA. The details of welded joint generated by class II electrode were measured and results were analysed in detail.

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.

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.

scholarly journals Selection of electrode tips for the resistance spot welding of dissimilar stainless steels

2018 ◽  
Vol 192 ◽  
pp. 01007 ◽  
Author(s):  
Teerawut Khuenkaew ◽  
Kannachai Kanlayasiri
Keyword(s):  
Resistance Spot Welding ◽  
Spot Welding ◽  
Indentation Depth ◽  
Welding Process ◽  
Single Type ◽  
Welding Parameters ◽  
Resistance Spot ◽  
Nugget Diameter ◽  
Steel Grades ◽  
Good Penetration

This research sought to resolve the issue of electrode tip selection used in the resistance spot welding for two different stainless steel grades under otherwise identical welding parameters: SUS316 and SUS425. The study used a full fractional design in order to perform the analysis of the variables involved, while the quality of the weld was assessed by considering the indentation depth, penetration, and nugget diameter. The results of the study described the nugget diameter and penetration for all welds with the various different electrode tips which met the specified requirements of the customers. A single type of upper R30 and lower R30 electrodes achieved acceptable indentation depth. Ideally, good weld quality would demand a large nugget diameter, shallow indentation, and good penetration, all contribution to an acceptable overall appearance. Both R30 electrode tips are able to achieve the desired quality requirements in the spot welding process.

The Influence of Welding Parameters on Effected the Complete for Resistance Spot Welding on Mild Steel

2011 ◽  
Vol 214 ◽  
pp. 113-117 ◽  
Author(s):  
Prachya Peasura
Keyword(s):  
Mild Steel ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Welding Process ◽  
Welding Current ◽  
Welding Parameters ◽  
Welding Time ◽  
Tensile Shear ◽  
Resistance Spot ◽  
Electrode Force

This research was study the effect of resistance spot welding process on physical properties. The specimen was mild steel sheet metal. The experiments with full factorial design. The factors used in this study are welding current, welding time and electrode force. The welded specimens were tested by tensile shear testing according to JIS Z 3136: 1999 and macro structure testing according to JIS Z 3139: 1978. The result showed that both of welding current, welding time and electrode force had interaction on tensile shear and nugget size at 95% confidential (P value < 0.05). Factors affecting the tensile shear and nugget size are the most welding current 10,000 amp., welding time 10 cycle and electrode force 1 kN. were tensile shear 7.13 kN. and nugget size maximum 6.75 mm. This research can bring information to the foundation in choosing the appropriate parameters to resistance spot welding process.

scholarly journals Short-Pulse Resistance Spot Welding of Aluminum Alloy 6016-T4 - Part 1

2021 ◽  
Vol 100 (01) ◽  
pp. 41-51
Author(s):  
ERIC SCHULZ ◽  
◽  
MATTHIAS WAGNER ◽  
HOLGER SCHUBERT ◽  
WENQI ZHANG ◽  
...  
Keyword(s):  
Aluminum Alloy ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Short Pulse ◽  
Welding Process ◽  
Welding Current ◽  
Welding Parameters ◽  
Resistance Spot ◽  
Pull Out ◽  
Welding Processes

Short-pulse welding parameters for resistance spot welding (RSW) of aluminum alloy AA6016-T4 using mediumfrequency direct current (MFDC) systems were developed to reduce the heat input required for nugget formation. Optimization of current and time parameters is critical during RSW of aluminum alloys for reducing energy requirements and avoiding weld imperfections, such as solidification cracking and expulsion, while maintaining weld quality, particularly given the high electrical and thermal conductivities of the materials. The welding time and the applied current level of the current pulse were varied systematically for thin sheets (1 mm or 0.04 in.) of AA6016-T4. The quality of the welds was evaluated by pull-out testing, ultrasound testing, and metallography techniques. Simulations of the same welding processes were performed with the finite element-based SORPAS® software. The results showed short-pulse MFDC RSW can reduce the energy required for sound welds in this alloy without requiring an increase in welding current. The simulations and experiments also showed the welding process had distinct weld nugget nucleation and growth phases.

THERMOMECHANICAL ANALYSIS OF THE RESISTANCE SPOT-WELDING PROCESS

2018 ◽  
Vol 10 (5) ◽  
pp. 449-455 ◽  
Author(s):  
Habib Lebbal ◽  
Lahouari Boukhris ◽  
Habib Berrekia ◽  
Abdelkader Ziadi
Keyword(s):  
Resistance Spot Welding ◽  
Spot Welding ◽  
Welding Process ◽  
Thermomechanical Analysis ◽  
Resistance Spot

Analysis of Electromagnetic Inverse Model of Resistance Spot Welding

2010 ◽  
Vol 160-162 ◽  
pp. 974-979
Author(s):  
Nai Feng Fan ◽  
Zhen Luo ◽  
Yang Li ◽  
Wen Bo Xuan
Keyword(s):  
Resistance Spot Welding ◽  
Regularization Method ◽  
Spot Welding ◽  
Influence Factors ◽  
Great Influence ◽  
Welding Process ◽  
Inverse Model ◽  
Resistance Spot ◽  
Inversion Theory

Resistance spot welding (RSW) is an important welding process in modern industrial production, and the quality of welding nugget determines the strength of products to a large extent. Limited by the level of RSW quality monitor, however, RSW has rarely been applied to the fields with high welding quality requirements. Associated with the inversion theory, in this paper, an electromagnetic inverse model of RSW was established, and the analysis of influence factors, such as the layout of the probes, the discrete program and the regularization method, was implemented as well. The result shows that the layout of the probe and the regularization method has great influence on the model. When the probe is located at the y direction of x-axis or the x direction of y-axis and Conjugate Gradient method is selected, a much better outcome can be achieved.

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