Resistance element welding of sandwich laminates with hidden inserts

2021 ◽  
Author(s):  
Francisco N. Calado ◽  
João P. M. Pragana ◽  
Ivo M. F. Bragança ◽  
Carlos M. A. Silva ◽  
Paulo A. F. Martins
Keyword(s):  
Resistance Element Welding

Resistance element welding of 7075 aluminum alloy to Ti6Al4V titanium alloy

2021 ◽  
Vol 70 ◽  
pp. 300-306
Author(s):  
Shuai Wang ◽  
Yang Li ◽  
Yue Yang ◽  
Sunusi Marwana Manladan ◽  
Zhen Luo
Keyword(s):  
Titanium Alloy ◽  
Aluminum Alloy ◽  
7075 Aluminum Alloy ◽  
Ti6al4v Titanium Alloy ◽  
Resistance Element Welding

scholarly journals Resistance Element Welding of Magnesium Alloy/austenitic Stainless Steel

2017 ◽  
Vol 238 ◽  
pp. 012004 ◽  
Author(s):  
S M Manladan ◽  
F Yusof ◽  
S Ramesh ◽  
Y Zhang ◽  
Z Luo ◽  
...  
Keyword(s):  
Stainless Steel ◽  
Magnesium Alloy ◽  
Austenitic Stainless Steel ◽  
Resistance Element Welding

scholarly journals FORMING PROCESS SIMULATION OF BIMETALLIC BILLET BY EXTRUSION FOR REW METHOD

2021 ◽  
Vol 27 (4) ◽  
pp. 210-213
Author(s):  
Alexander Schrek ◽  
Alena Brusilová ◽  
Pavol Sejč ◽  
Branislav Vanko
Keyword(s):  
Cross Section ◽  
Lap Joints ◽  
Outer Diameter ◽  
Ansys Software ◽  
Forming Process ◽  
Cold Forming ◽  
Forming Simulation ◽  
Resistance Element Welding ◽  
Extrusion Forming ◽  
Cross Section Geometry

The bimetallic joining elements were designed for lap joints of thin metallic (Fe-Fe, Fe-Al) as well as metallic – nonmetallic (Fe-PMMA, Al-PMMA) sheets by Resistance Element Welding (REW). The Cu tubes with an outer diameter of 4 mm, wall thickness of 0.5 mm, and a length of 11 mm filled with a solder Sn60Pb40 were used for the bimetallic joining elements producing. The required shape of joining elements is obtained by cold forming. Simulation by ANSYS software was chosen for the optimization of the forming process and geometry of functional parts of the forming tool allowing to use only one extrusion forming operation. The simulation results are stresses, strains, and modification of cross-section geometry of elements for the three proposed forming modes. The geometry of functional parts of the forming tool was compared with the results of cross-section macroanalysis of joining elements.

Resistance Element Welding of 6061 Aluminum Alloy to Uncoated 22MnMoB Boron Steel

2016 ◽  
Vol 31 (16) ◽  
pp. 2174-2180 ◽  
Author(s):  
Zhanxiang Ling ◽  
Yang Li ◽  
Zhen Luo ◽  
Yueqiao Feng ◽  
Zhengmin Wang
Keyword(s):  
Aluminum Alloy ◽  
Boron Steel ◽  
6061 Aluminum Alloy ◽  
Resistance Element Welding

scholarly journals Joining of Thermoplastic Composites with Metals Using Resistance Element Welding

2020 ◽  
Vol 10 (20) ◽  
pp. 7251 ◽  
Author(s):  
Juliane Troschitz ◽  
Julian Vorderbrüggen ◽  
Robert Kupfer ◽  
Maik Gude ◽  
Gerson Meschut
Keyword(s):  
Welding Process ◽  
Thermoplastic Composites ◽  
Innovative Technology ◽  
Welding Parameters ◽  
Compression Moulding ◽  
Steel Sheets ◽  
Lap Shear ◽  
Before And After ◽  
Resistance Element Welding ◽  
Glass Fibre Reinforced

Joining is a key enabler for a successful application of thermoplastic composites (TPC) in future multi-material systems. To use joining technologies, such as resistance welding for composite-metal joints, auxiliary joining elements (weld inserts) can be integrated into the composite and used as an interface. The authors pursue the approach of embedding metal weld inserts in TPC during compression moulding without fibre damage. The technology is based on the concept of moulding holes by a pin and simultaneously placing the weld insert in the moulded hole. Subsequently, the composite component can be joined with metal structures using conventional spot welding guns. For this purpose, two different types of weld inserts were embedded in glass fibre reinforced polypropylene sheets and then welded to steel sheets. A simulation of the welding process determined suitable welding parameters. The quality of the joints was analysed by microsections before and after the welding process. In addition, the joint strength was evaluated by chisel tests as well as single-lap shear tests for the different weld insert designs. It could be shown that high-quality joints can be achieved by using the innovative technology and that the load-bearing capacity is significantly influenced by the weld inserts head design.

scholarly journals Preventing Nugget Shifting in Joining of Dissimilar Steels via Resistance Element Welding: A Numerical Simulation.

2021 ◽  
Author(s):  
Zhenghua Rao ◽  
Lei Liu ◽  
Yaqiong Wang ◽  
Liang Ou ◽  
Jiangwei Liu
Keyword(s):  
Spot Welding ◽  
High Strength Steels ◽  
High Strength ◽  
Critical Issue ◽  
Resistivity Ratio ◽  
Dp Steel ◽  
Advanced High Strength Steels ◽  
High Electrical Resistivity ◽  
Resistance Element Welding ◽  
Welding Element

Abstract Joining the advanced high strength steels and the conventional steels is a critical issue for the manufacturing of lightweight vehicles. Resistance element welding (REW) is an emerging joining method for dissimilar metals and alloys by applying an auxiliary rivet-like resistance element in resistance spot welding (RSW). In this study, an electrical-thermal-mechanical coupled REW model for high-strength dual-phase (DP) steel and Q235 steel was developed by considering contact resistances as functions of temperature and surface contacting area. The results show that the welding element in REW serves to concentrate the current flow and thus Joule heat generation at the faying interface between the element and workpiece. For welding DP600 and Q235 workpieces with a small thickness ratio (≤0.4) or a high electrical resistivity ratio (≥3), REW could effectively mitigate nugget shifting between workpieces and reducing the thermal excursion to electrode as compared to RSW. Adding well-designed insulation layers in REW could further concentrate the current within the welding element, and enables a large-sized nugget at a lower current. This study is significant because it provides a better understanding to the electrical-thermal-mechanical behaviors with interfacial contacts in REW and contributes to its further advance.

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