The Importance of Governing Metal Thickness for Resistance Spot Welding of Aluminium

2011 ◽  
Vol 473 ◽  
pp. 319-326
Author(s):  
Li Han ◽  
Martin Thornton ◽  
Douglas Boomer ◽  
M. Shergold
Keyword(s):  
Resistance Spot Welding ◽  
Spot Welding ◽  
Joint Strength ◽  
Loading Conditions ◽  
Weld Quality ◽  
Welding Quality ◽  
Resistance Spot ◽  
Lap Shear ◽  
Metal Thickness ◽  
Cross Tension

A study was carried out to investigate the effect of governing metal thickness (GMT) on weld quality and strength of resistance spot welded (RSW) AA5754 aluminium. Quasi-static joint strengths were evaluated for 27 different joint stack-ups in three test geometries: lap-shear, coachpeel and cross-tension; whilst micro examination was conducted on some of the samples to assess weld quality. The results derived from over 1000 samples show the importance of GMT and its various effects: the GMT has a significant effect on welding quality and joint strength by controlling the attainable weld diameter, regardless of stack-ups; depending on loading conditions, its effect may differ.

Effect of Gap between Steel Sheet and Electrode on Resistance Spot Welding

2018 ◽  
Vol 941 ◽  
pp. 158-163 ◽  
Author(s):  
Sho Matsui ◽  
Chisato Wakabayashi ◽  
Shinji Kodama
Keyword(s):  
Resistance Spot Welding ◽  
Spot Welding ◽  
Joint Strength ◽  
Steel Sheet ◽  
High Tensile Strength ◽  
Resistance Spot ◽  
Steel Sheets ◽  
Tension Tests ◽  
Cross Tension

If resistance spot welding (RSW) is conducted when there is a gap between a steel sheet and an unmovable electrode, the steel sheets are bended by a movable electrode, and the quality of RSW is influenced. Therefore, it is necessary to understand the effect of the gap on RSW. In this study, two high-tensile strength steel sheets were welded with the gap. In addition, cross-section observations and cross tension tests were conducted to verify the effect of the gap on weldability and joint strength. Consequently, two notable results were obtained. First, the observation indicated that deformation around the corona-bond was varied depending on the gap. Second, the cross tension tests showed that the gap decreased the joint strength even though the nugget was large enough. These result indicated that controlling the gap is important to ensure the quality of RSW.

A Comprehensive Approach for Resistance Spot Welding Quality Estimation Using Dynamic Resistance Based Model

2012 ◽  
Vol 249-250 ◽  
pp. 732-738
Author(s):  
A. El Ouafi ◽  
R. Belanger ◽  
M. Guillot
Keyword(s):  
Quality Indicators ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Welding Parameters ◽  
Dynamic Resistance ◽  
Weld Quality ◽  
Welding Quality ◽  
Quality Estimation ◽  
Resistance Spot ◽  
On Line

On-line quality assessment becomes one of the most critical requirements for improving the efficiency of automatic resistance spot welding (RSW) processes. Accurate and efficient model to perform non-destructive quality estimation is an essential part of the assessment. Besides the usual welding parameters, various measured variables have been considered for quality estimation in RSW. Among these variables, dynamic resistance gives a relative clear picture of the welding nugget formation and presents a significant correlation withseveral RSW quality indicators. This paper presents a structuredand comprehensiveapproach developed to design an effective dynamic resistancebased model for on-line quality estimation in RSW. The proposed approach examines welding parameters and conditions known to have an influence on weld quality, and builds a quality estimation model step by step. The modeling procedure begins by examining, through a structured experimental design, the relationships between welding parameters, typical characteristics of the dynamic resistance curves and multiple welding quality indicators. Using these results and various statistical tools, different integrated quality estimation models combining an assortment of dynamic resistance attributes are developed and evaluated. The results demonstrate that the proposed approach can lead to a consistentmodel able to accurately and reliably provide an appropriate estimationof the weld quality under variable welding conditions.

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