Optimization of Resistance Spotwelding Parameters Using Taguchi Method

2018 ◽  
Vol 6 (7) ◽  
pp. 196
Author(s):  
Shailesh Kumar Vishwakarma ◽  
Anurag Shrivastava ◽  
Sharmistha Singh
Keyword(s):  
Tensile Strength ◽  
Taguchi Method ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Experimental Studies ◽  
Welding Current ◽  
Resistance Spot ◽  
Nugget Diameter ◽  
Time Parameters ◽  
Welding Processes

Resistance spot welding (RSW) is a major sheet metal joining process in many industries, such as the automobile, domestic appliances, and space craft fabrication. It is one of the oldest of the electric welding processes in use by industry today. Furthermore, other metal-to-metal connections, such as wire-to-wire joints in the electronics industry, are accomplished by resistance spot welding. Application-specific measures, such as the diameter of the welding spot, define the quality of the joint. The weld is made by a combination of heat, pressure, and time parameters. As the name implies, it uses the resistance of the materials to the flow of electric current that causes a localized heating in the parts to be joined. Understanding of physical mechanisms for easily manipulating and controlling weld qualities in advance is extremely important. This paper represents the optimization of various parameters of resistance spot welding. The experimental studies have been conducted under varying pressure, welding current, pressure, and welding time parameters. In this investigation the quality characteristic (tensile strength and nugget diameter) parameters have been considered using Taguchi Method. The experimental studies have been carried out by varying welding currents, welding pressure and weld times for joining two sheets. The results of the investigation indicate the welding current to be the most significant parameter controlling the weld tensile strength as well as the nugget diameter. The contribution of welding current, holding time and pressure to tensile strength are 61%, 29%, 4% respectively and the contribution of these parameters to nugget diameter are 81%, 1.7%, 17% respectively. Relationship graphs have been plotted between tensile strength and nugget diameter with parametric variations according to orthogonal array.

Dynamic Electrode Force and Displacement in Resistance Spot Welding of Aluminum

2004 ◽  
Vol 126 (3) ◽  
pp. 605-610 ◽  
Author(s):  
C. T. Ji, ◽  
Y. Zhou,
Keyword(s):  
Resistance Spot Welding ◽  
Spot Welding ◽  
Welding Current ◽  
Monitoring And Control ◽  
Resistance Spot ◽  
Nugget Diameter ◽  
Electrode Force ◽  
Rate Of Increase ◽  
Process Monitoring And Control ◽  
Electrode Displacement

Dynamic electrode displacement and force were characterized during resistance spot welding of aluminum alloy 5182 sheets using a medium-frequency direct-current welder. It was found that both electrode displacement and force increased rapidly at the beginning of the welding stage and then at a reducing rate. Rates of increase in electrode displacement and force were both proportional to welding current. And both electrode displacement and force experienced a sudden drop when weld metal expulsion occurred. However, the rate of increase in electrode displacement did not reach zero during welding even for joints with sufficient nugget diameter, while electrode force peaked when a large nugget diameter was produced. Possible strategies for process monitoring and control were also discussed.

A Comparative Study of AC and MFDC Resistance Spot Welding

2004 ◽  
Author(s):  
Wei Li ◽  
Daniel Cerjanec
Keyword(s):  
Comparative Study ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Welding Process ◽  
Welding Current ◽  
Median Frequency ◽  
Resistance Spot ◽  
Secondary Voltage ◽  
Nugget Growth ◽  
Welding Processes

This paper presents a comparative study of the AC and MFDC resistance spot welding process. Two identical welders were used; one with a single phase AC and the other with a median frequency DC weld control. Both welders were instrumented such that the primary and secondary voltage and current could be collected. A nugget growth experiment was conducted to compare the weld size and energy consumption in the AC and MFDC welding processes. It is found that the MFDC process generally produces larger welds with the same welding current. However, this difference is more prominent when the welding current is low. Overall the AC welding process consumes more energy to make a same size weld. The larger the welding current is used, the less efficient the AC process becomes.

Evaluation of the Role of Eddy Current in Resistance Spot Welding

2009 ◽  
Vol 131 (6) ◽  
Author(s):  
M. Abu-Aesh ◽  
Moataza Hindy
Keyword(s):  
Eddy Current ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Welding Process ◽  
Welding Current ◽  
Work Piece ◽  
Resistance Spot ◽  
Precise Prediction ◽  
Welding Processes

Extensive work had been conducted on spot-welding due to its rapidly increasing industrial importance. The resistance spot-welding involves complicated phenomena, as several effects are found in the process, e.g., temperature, surface roughness, pressure, and eddy current effects. Most of the work exerted for analyzing the spot-welding process neglect the effect of the eddy current generated during the flow of the huge welding main current through the assembly of electrodes and work sheets. This work presents an analytical method to investigate the generation of eddy current and to determine the total effective welding current in spot-welding. The current distribution on the work sheet when it is fed by a conducting electrode is also investigated. The obtained current formula is based on electromagnetic principles, where a very strong magnetic field is generated in the core of the electrodes as well as in the materials of work sheets due to the flow of very high amperage. The final resultant effective current is the superposition of the electrode welding current and the induced eddy current in the electrode and work piece assembly. The results offer a viable mathematical model, which can be applied for a precise prediction of the effective value of welding current in spot-welding processes, if applied in a comprehensive model including all involved effects.

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.

STRENGTH CHARACTERISTICS ON RESISTANCE SPOT WELDING OF Al ALLOY SHEETS BY TAGUCHI METHOD

2006 ◽  
Vol 20 (25n27) ◽  
pp. 4297-4302 ◽  
Author(s):  
HAN-KI YOON ◽  
BYEONG-HYEON MIN ◽  
CHIL-SOON LEE ◽  
DO-HYOUNG KIM ◽  
YOUN-KYOUM KIM ◽  
...  
Keyword(s):  
Experimental Design ◽  
Taguchi Method ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Welding Current ◽  
Al Alloy ◽  
Welding Time ◽  
Tensile Shear ◽  
Resistance Spot ◽  
Electrode Force

Optimal welding condition in resistance spot welding of 7075-T6 aluminum alloy sheets with the thickness of 0.4mm was investigated by the tensile-shear strength tests and Taguchi method in experimental design with changing various welding conditions respectively. The tensile-shear tests were carried out at cross-head speeds of 0.1mm/min in accordance with the KS B0851. Design methods were systematically performed using an L27(39) orthogonal array table. In the experimental design, three control factors of resistance spot welding conditions were electrode force, welding current and welding time. Electrode force conditions were 882N, 1323N and 1764N, and welding current were 13.5kA, 14kA and 14.5kA, and welding time were 3cycle, 4cycle and 5cycle.

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%.

Investigation on Joining Mechanism of SiC Particle Reinforced Aluminum Matrix Composite (Al/SiCp-MMC) by Resistance Spot Welding

2011 ◽  
Vol 704-705 ◽  
pp. 1399-1405
Author(s):  
Xing Rui Li ◽  
Wen Bo Tang ◽  
Ji Tai Niu
Keyword(s):  
Matrix Composite ◽  
Welded Joints ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Welding Current ◽  
Welding Parameters ◽  
Resistance Spot ◽  
Composite Joint ◽  
Welding Processes ◽  
Sic Particle

The present study had investigated the joining performance of SiC particle reinforced aluminum metal matrix composite (Al/SiCp-MMC) having 1.0mm thickness by resistance spot welding processes. The welded joints were subjected to tensile-shearing tests in order to determine the strength of the welded zone. In addition both scanning electron microscopy (SEM) and optical microscopy (OM) were conducted to investigate the micro structural and micro hardness’s changes of the welded joints. The results reveal that: the maximum tensile-shear strength value of welded joint was obtained in these optimum welding parameters as in 17.5kA welding current for 60 periods welding. The electrode pressure was 3.5kN. It was favorable to select relatively high welding current and short welding time for improving mechanical properties of spot welded SiCp/LY12 composite joint. In this base, the welding mechanism of resistance spot welding SiCp/LY12 composite has also been discussed in detail.

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.

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