scholarly journals Microstructure and Failure Analysis of Resistance Projection Welding of Nuts to AHSS with Capacitor Discharge Welding

2019 ◽  
Vol 59 (2) ◽  
pp. 305-311
Author(s):  
Jiehan Luo ◽  
Zhaoyao Zhou ◽  
Xiaobing Cao ◽  
Chunhua Zou ◽  
Chunya Zou
Keyword(s):  
Failure Analysis ◽  
Capacitor Discharge ◽  
Projection Welding ◽  
Capacitor Discharge Welding

scholarly journals Performing an Indirect Coupled Numerical Simulation for Capacitor Discharge Welding of Aluminium Components

Processes ◽  
2020 ◽  
Vol 8 (11) ◽  
pp. 1330
Author(s):  
Johannes Koal ◽  
Martin Baumgarten ◽  
Stefan Heilmann ◽  
Jörg Zschetzsche ◽  
Uwe Füssel
Keyword(s):  
Electrical Contact ◽  
Electrical Contact Resistance ◽  
Capacitor Discharge ◽  
Projection Welding ◽  
Indirect Coupling ◽  
Physical Environments ◽  
Process Characterization ◽  
Experimental Process ◽  
Capacitor Discharge Welding

Capacitor discharge welding (CDW) for projection welding provides very high current pulses in extremely short welding times. This requires a quick follow up behaviour of the electrodes during the softening of the projection. The possibilities of experimental process investigations are strongly limited because of the covered contact zone and short process times. The Finite Element Method (FEM) allows highly resoluted analyses in time and space and is therefore a suitable tool for process characterization and optimization. To utilize this mean of optimization, an indirect multiphysical numerical model has been developed in Ansys Mechanical APDL. This model couples the physical environments of thermal–electric with structural analysis. It can master the complexity of large deformations, short current rise times and high temperature gradients. A typical ring projection has been chosen as the joining task. The selected aluminium alloys are EN-AW-6082 (ring projection) and EN-AW-5083 (sheet metal). This paper presents the investigated material data, the model design and the methodology for an indirect coupling of the thermal–electric with the structural physic. The electrical contact resistance is adapted to the measured voltage in the experiment. The limits of the model in Ansys Mechanical APDL are due to large mesh deformation and decreasing element stiffness. Further modelling possibilities, which can handle the limits, are described.

Interfacial structures of dissimilar materials joined by capacitor-discharge welding

1994 ◽  
Vol 52 ◽  
pp. 534-535
Author(s):  
C. P. Doğan ◽  
R. D. Wilson ◽  
J. A. Hawk
Keyword(s):  
Rapid Solidification ◽  
Fusion Zone ◽  
Dissimilar Materials ◽  
Solidification Process ◽  
Weld Interface ◽  
Capacitor Discharge ◽  
Fine Grained ◽  
Iron Aluminum ◽  
Conductive Ceramics ◽  
Capacitor Discharge Welding

Capacitor Discharge Welding is a rapid solidification technique for joining conductive materials that results in a narrow fusion zone and almost no heat affected zone. As a result, the microstructures and properties of the bulk materials are essentially continuous across the weld interface. During the joining process, one of the materials to be joined acts as the anode and the other acts as the cathode. The anode and cathode are brought together with a concomitant discharge of a capacitor bank, creating an arc which melts the materials at the joining surfaces and welds them together (Fig. 1). As the electrodes impact, the arc is extinguished, and the molten interface cools at rates that can exceed 106 K/s. This process results in reduced porosity in the fusion zone, a fine-grained weldment, and a reduced tendency for hot cracking.At the U.S. Bureau of Mines, we are currently examining the possibilities of using capacitor discharge welding to join dissimilar metals, metals to intermetallics, and metals to conductive ceramics. In this particular study, we will examine the microstructural characteristics of iron-aluminum welds in detail, focussing our attention primarily on interfaces produced during the rapid solidification process.

Effect of Capacitor Discharge Welding on Single-Crystal Metals

2000 ◽  
Vol 2 (3) ◽  
pp. 143-150
Author(s):  
Brian K. Paul ◽  
Wiwat Thaneepakorn ◽  
Rick D. Wilson
Keyword(s):  
Single Crystal ◽  
Capacitor Discharge ◽  
Capacitor Discharge Welding

Thermal Analysis of Capacitor Discharge Welding and its Correlation With Observed Stress Wave Emission (SWE)

1977 ◽  
Vol 99 (4) ◽  
pp. 379-386
Author(s):  
U. C. Paek ◽  
S. J. Vahaviolos ◽  
G. E. Kleinedler
Keyword(s):  
Thermal Analysis ◽  
Stress Wave ◽  
Weld Zone ◽  
Frequency Discrimination ◽  
Signal Frequency ◽  
Depth Of Penetration ◽  
Conduction Model ◽  
Capacitor Discharge ◽  
Wave Emission ◽  
Capacitor Discharge Welding

A theoretical approach to thermal analysis of capacitor discharge welding is presented. The weld current is divided into three segments (premelting, melting, and postmelting) and each is analyzed with a one dimensional heat conduction model. From this analysis, normalized parameter values are plotted to provide an estimate of the thermal time constant of welding and the extent of melting. The predicted weld zone depth of penetration was experimentally verified with metallographic data. Similarly, using signal frequency discrimination techniques, it was found that Stress Wave Emission (SWE) techniques could be adapted to measure the parameters of the above three pulse segments (tm, te, tc) accurately and in real time. Theoretical and experimental metallographic and SWE results are in good agreement.

scholarly journals Percussion capacitor-discharge welding of wire of composite superconducting alloy

2014 ◽  
Vol 2014 (4) ◽  
pp. 37-39
Author(s):  
D.M. Kaleko ◽  
Keyword(s):  
Capacitor Discharge ◽  
Capacitor Discharge Welding

Current Distribution Monitoring in Capacitor Discharge Welding

2020 ◽  
Author(s):  
Moritz Meiners ◽  
Tobias Reichenstein ◽  
Jorg Franke ◽  
Rainer Hauenstein
Keyword(s):  
Current Distribution ◽  
Capacitor Discharge ◽  
Capacitor Discharge Welding

Design and Measurements of Capacitor Discharge Welding Transformers

1946 ◽  
Vol 65 (3) ◽  
pp. 154-159
Author(s):  
T. W. Dietz ◽  
G. M. Stein
Keyword(s):  
Capacitor Discharge ◽  
Capacitor Discharge Welding

scholarly journals Impulse capacitor discharge welding of hollow structure made of nickel-base alloy

2007 ◽  
Vol 12 (4) ◽  
pp. 453-458 ◽  
Author(s):  
Jianzhao Wang ◽  
Ohse Peter ◽  
Su Wu ◽  
Dilthey Ulrich
Keyword(s):  
Base Alloy ◽  
Hollow Structure ◽  
Nickel Base Alloy ◽  
Capacitor Discharge ◽  
Nickel Base ◽  
Capacitor Discharge Welding

Rapid Solidification Joining of Intermetallics using Capacitor Discharge Welding

1994 ◽  
Vol 364 ◽  
Author(s):  
R. D. Wilson ◽  
D. E. Alman ◽  
J. A. Hawk
Keyword(s):  
Rapid Solidification ◽  
Fusion Zone ◽  
Arc Welding ◽  
Gas Tungsten Arc Welding ◽  
Experimental Results ◽  
Solidification Microstructure ◽  
Capacitor Discharge ◽  
Gas Tungsten Arc ◽  
Joining Process ◽  
Capacitor Discharge Welding

AbstractCapacitor Discharge Welding (CDW) is a rapid solidification joining process capable of cooling rates greater than 106 K/s. The Bureau of Mines is investigating the CDW process as a method of joining TiAl, Fe3A1 and MoSi2. Experimental results show that the fusion zone of the CDW welds is less than 0.1 mm wide, is uniform in composition, and has a cellular solidification microstructure. This paper compares the CDW microstructure of several intermetallics to the microstructures obtained from the gas tungsten arc welding.

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