Numerical Analysis of the Effect of Electrode Strips on Spot-Welding Process

2020 ◽  
Vol 837 ◽  
pp. 58-63
Author(s):  
Xiao Hui Han ◽  
Ye Xu ◽  
Sen Guo ◽  
Cheng Jin
Keyword(s):  
Numerical Analysis ◽  
Spot Welding ◽  
Manufacturing Industry ◽  
Indentation Depth ◽  
Welding Process ◽  
Processing Parameters ◽  
Weld Nugget ◽  
Mechanical Coupling ◽  
Nugget Formation ◽  
Mechanical Physics

Resistance spot welding is an important technology widely used in manufacturing industry. It is a coupling process which involves thermal, electrical and mechanical physics fields. Due to the formation of weld nugget is transient and non-visible, the experimental analysis is difficult. In this paper, a thermal electrical-mechanical coupling technique is carried out by finite element method to study the effect of electrode strips on weld nugget formation and surface indentation under different processing parameters. Experimental and numerical analysis results show that the electrode strips can reduce the surface indentation depth effectively and is helpful to the formation of weld nugget.

Numerical Analysis of Transport Phenomena in Resistance Spot Welding Process

2011 ◽  
Vol 133 (3) ◽  
Author(s):  
YongBing Li ◽  
ZhongQin Lin ◽  
Qi Shen ◽  
XinMin Lai
Keyword(s):  
Mass Transport ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Welding Process ◽  
Weld Nugget ◽  
Temperature Dependent ◽  
Resistance Spot ◽  
Nugget Formation ◽  
Thermal Fluid Flow ◽  
Transport Laws

Resistance spot welding (RSW) is a very complicated process involving electromagnetic, thermal, fluid flow, mechanical, and metallurgical variables. Since weld nugget area is closed and unobservable using experimental means, numerical methods are generally used to reveal the nugget formation mechanism. Traditional RSW models focus on the electrothermal behaviors in the nugget and do not have the ability to model mass transport caused by induced magnetic forces in the molten nugget. In this paper, a multiphysics model, which comprehensively considers the coupling of electric, magnetic, thermal, and flow fields during RSW, temperature-dependent physical properties, and phase transformation, is used to investigate the heat and mass transport laws in the weld nugget and to reveal the interaction of the heat and mass transports and their evolutions. Results showed that strong and complicated mass transport appears in the weld nugget and substantially changed the heat transport laws and, therefore, would be able to substantially affect the hardening, segregation, and residual stress of the weld. Compared with the traditional models which could not consider the mass transport, the multiphysics model proposed in this paper could simulate the RSW process with higher accuracy and more realities.

Numerical Analysis of Transport Phenomena in Resistance Spot Welding Process

2009 ◽  
Author(s):  
Yong Bing Li ◽  
Zhong Qin Lin ◽  
Li Li ◽  
Guan Long Chen
Keyword(s):  
Mass Transport ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Welding Process ◽  
Weld Nugget ◽  
Resistance Spot ◽  
Nugget Formation ◽  
Electro Magnetic ◽  
Physics Model ◽  
Thermal Fluid Flow

Resistance Spot Welding (RSW) is a very complicated process involving electro-magnetic, thermal, fluid flow, mechanical and metallurgical variables. Since weld nugget area is close and unobservable with experimental means, numerical methods are mainly used to reveal the nugget formation mechanism. Traditional RSW models focus on the electro-thermal behaviors in the nugget, and do not have the ability to model mass transport caused by induced magnetic forces in the molten nugget. In this paper, a multi-physics model, which comprehensively considers the coupling of electric, magnetic, thermal and flow fields during RSW, temperature-dependent physical properties and phase transformation, is used to investigate the heat and mass transport laws in the weld nugget and to reveal the interaction of the heat and mass transports. Results show that the heat transport behaviors in the weld nugget, the profile of the nugget, and the thermal field evolution are significantly changed when the mass transport is considered. At the same time, a good agreement is also found between experimental and numerically calculated nugget sizes. As a result, when predicting crystal growth process, the effects of the mass transport should be considered in order to obtain a more accurate prediction results.

scholarly journals Effect of Zinc Coating on Delay Nugget Formation in Dissimilar DP600 - AISI304 Welded Joints Obtained by the Resistance Spot Welding Process

2021 ◽  
Author(s):  
Mercedes Pérez de la Parte ◽  
Alejandro Espinel Hernández ◽  
Mario César Sánchez Orozco ◽  
Angel Sánchez Roca ◽  
Emilio Jiménez Macias ◽  
...  
Keyword(s):  
Welded Joints ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Zinc Coating ◽  
Welding Process ◽  
Dynamic Resistance ◽  
Time Duration ◽  
Resistance Spot ◽  
Nugget Formation ◽  
Resistance Curves

Abstract This paper researches the effect of zinc coating of galvanized DP600 steel on the dynamic resistance and the delayed nugget formation of dissimilar DP600 - AISI304 welded joints, obtained with resistance spot welding process (RSW). The RSW evaluations consisted of determining, from the dynamic resistance curves, the time involved in the different stages of the process, particularly the beginning of nugget formation. The experimental results showed that, from the dynamic resistance curves, it is possible to identify 8 distinct stages during the welding of galvanized DP600 steel and AISI304 stainless steel. In the case of the welding of uncoated DP600 steel with AISI304, only 6 stages are identified (except for stages 2 and 3), which are directly related to the heating, softening and melting of the galvanic coating. The energy used in stages 2 and 3, causes a delay in the beginning of nugget formation for welded joints obtained with galvanized DP600 steel compared to uncoated DP600 - AISI304 welded joints, reaching values between 37.28 ms and 52.29 ms for the welding conditions analyzed. Monitoring the time duration of stages 2 and 3, as defined from the analysis of the dynamic resistance curves, could be used as a tool to predict the beginning of nugget formation in the welding of galvanized steels, to avoid undesirable phenomena such as expulsion and to guarantee the quality of the welded joints.

Numerical simulation of weld nugget in resistance spot welding process

2020 ◽  
Vol 27 ◽  
pp. 2958-2963
Author(s):  
Abhishek Kumar ◽  
Sikta Panda ◽  
Gaurab Kumar Ghosh ◽  
Ritesh Kumar Patel
Keyword(s):  
Numerical Simulation ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Welding Process ◽  
Weld Nugget ◽  
Resistance Spot

Study on Intermediate Frequency Spot Welding Process of Hot Stamping High Strength Steel

2011 ◽  
Vol 339 ◽  
pp. 375-378 ◽  
Author(s):  
Yang Yu ◽  
Chao Wang ◽  
Shu Jun Chen ◽  
Zhen Yang Lu
Keyword(s):  
Base Metal ◽  
Fracture Mode ◽  
Spot Welding ◽  
Hot Stamping ◽  
Welding Process ◽  
Welding Current ◽  
High Strength ◽  
Intermediate Frequency ◽  
Weld Nugget ◽  
Micro Hardness

The joints of RSW for HSHSS were prepared with IF spot weld equipment. The weld nugget, fracture mode, microstructure and micro-hardness of the joints were investigated. The weld nugget increases and the fracture mode changes from interfacial fracture to nugget plug fracture with the increasing welding current. There are three distinct zones in the weld joint: weld nugget, heat affected zone (HAZ) and base metal. The microstructure of HAZ includes tempered zone (HAZ-1), incomplete quenching zone (HAZ-2) and complete quenching zone (HAZ-3). The micro-hardness of weld nugget and HAZ-3 is same with the base metal. The micro-hardness of HAZ-1 and HAZ-2 is smaller than that of base metal.

Numerical analysis of single sided spot welding process used in sheet to tube joining

2006 ◽  
Vol 11 (5) ◽  
pp. 609-617 ◽  
Author(s):  
C.-P. Liang ◽  
Z.-Q. Lin ◽  
G.-L. Chen ◽  
Y.-B. Li
Keyword(s):  
Numerical Analysis ◽  
Spot Welding ◽  
Welding Process

Simulation Analysis on the Contact Status during Sheet-to-Tube Single Sided Spot Welding Process

2013 ◽  
Vol 815 ◽  
pp. 742-746
Author(s):  
Cai Ping Liang ◽  
Ning Li ◽  
Fang Fang Sun
Keyword(s):  
Spot Welding ◽  
Simulation Analysis ◽  
Dynamic Change ◽  
Welding Process ◽  
Automobile Manufacturing ◽  
Vehicle Structure ◽  
Tube Welding ◽  
Nugget Formation ◽  
Current Stage

Single sided resistance spot welding (SSRSW) developed from RSW is a feasible plan to join vehicle structure to closed-form tube and is increasingly used in automobile manufacturing. During the process of SSSW, large deformation and complex contact status of the workpieces occur because there is no inside support. The complex contact status has directly influence on the size of the nugget which is critical to the quality of welding. In this study, the contact statuses during the current stage of sheet-to-tube spot welding were researched by numerical method. It was found that the widths of the contact regions of electrode to sheet and sheet and sheet to tube have dynamic change during welding process which decided the size and speed of the nugget formation. The results have direct guiding significance to the study on ring nugget formation during sheet-to-tube welding.

The Influence of Interfacial Thermal Contact Conductance on Resistance Spot Weld Nugget Formation

2010 ◽  
Vol 97-101 ◽  
pp. 3239-3242 ◽  
Author(s):  
Yong Bing Li ◽  
Xin Min Lai ◽  
Guan Long Chen
Keyword(s):  
Surface Roughness ◽  
Numerical Models ◽  
Thermal Contact ◽  
Welding Process ◽  
Weld Nugget ◽  
Thermal Contact Conductance ◽  
Contact Conductance ◽  
Resistance Spot ◽  
Roughness Surface ◽  
Nugget Formation

Resistance spot welding process is strongly related to interfacial contact behaviors. The effects of thermal contact is rarely investigated so far and generally ignored in numerical models. In this work, a parametric FE model, which considers the variation of the surface roughness of the electrodes and workpieces, has been developed to investigate the effects of thermal contact on weld nugget formation. With the parametric model, four cases, e.g. ideal smooth surface, minimal roughness surface and maximum roughness surface for steel sheets and electrodes of as-received condition, and highly rough electrode surface, are investigated. Researches show that when the surface roughness of the electrodes exceeds some limit, the thermal contact conductance will substantially affect the weld nugget formation, therefore, must be considered in numerical models to precisely predict welding process.

Weld nugget formation in resistance spot welding of new lightweight sandwich material

2015 ◽  
Vol 80 (5-8) ◽  
pp. 1137-1147 ◽  
Author(s):  
J. Sagüés Tanco ◽  
C. V. Nielsen ◽  
A. Chergui ◽  
W. Zhang ◽  
N. Bay
Keyword(s):  
Resistance Spot Welding ◽  
Spot Welding ◽  
Weld Nugget ◽  
Resistance Spot ◽  
Nugget Formation
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