Axisymmetric Nugget Growth During Resistance Spot Welding

1990 ◽  
Vol 112 (2) ◽  
pp. 309-316 ◽  
Author(s):  
P. S. Wei ◽  
C. Y. Ho
Keyword(s):  
Experimental Data ◽  
Heat Generation ◽  
Joule Heating ◽  
Spot Welding ◽  
Early Stage ◽  
Three Dimensional ◽  
Weld Nugget ◽  
Faying Surface ◽  
Nugget Growth ◽  
Radial Heat

Three-dimensional weld nugget growths for different welding currents, electrode tip shapes, and thickness ratios of workpieces are determined. By providing an effective model to estimate the heat generation at the faying surface between workpieces and taking into account the phase change due to melting, results show that the calculated weld nugget growth, nugget thickness, and shape of the nugget agree well with experimental data. Heat generation at the faying surface in the early stage of welding and joule heating at long weld times dominate the nugget growth. Consideration of radial heat loss is necessary at longer weld times and higher welding currents.

Thermomechanical Model of Spot Welding for Calculating Residual Stresses

2003 ◽  
Author(s):  
Lijun Xu ◽  
Jamil A. Khan
Keyword(s):  
Residual Stresses ◽  
Heat Generation ◽  
Spot Welding ◽  
Welding Process ◽  
Mechanical Analysis ◽  
Temperature Dependent ◽  
Thermomechanical Model ◽  
Faying Surface ◽  
Proposed Model ◽  
Electrode Interface

A comprehensive axisymmetric model of the coupled thermal-electrical-mechanical analysis predicting weld nugget development and residual stresses for the resistance spot welding process of Al-alloys is developed. The model estimates the heat generation at the faying surface, the workpiece-electrode interface, and the Joule heating of the workpiece and electrode. The phase change due to melting in the weld pool is considered. The contact area and its pressure distribution at both the faying surface and the electrode-workpiece interface are determined from a coupled thermal-mechanical model using a finite element method. The knowledge of the interface pressure provides accurate prediction of the interfacial heat generation. For the numerical model, temperature dependent thermal, electrical and mechanical properties are used. The proposed model can successfidly calculate the nugget diameter and thickness, and predict the residual stresses and the elastic-plastic deformation history. The calculated nugget shape and the deformation of sheets based on the model are compared with the experimental data. The computed residual stresses approach the distribution of experimental measurement of the residual stress.

Simulating Thermoelectric Effect and Its Impact on Asymmetric Weld Nugget Growth in Aluminum Resistance Spot Welding

2020 ◽  
Vol 142 (9) ◽  
Author(s):  
Lin Deng ◽  
YongBing Li ◽  
Wayne Cai ◽  
Amberlee S. Haselhuhn ◽  
Blair E. Carlson
Keyword(s):  
Resistance Spot Welding ◽  
Spot Welding ◽  
Weld Nugget ◽  
Thermoelectric Effects ◽  
Element Analysis ◽  
Resistance Spot ◽  
Seebeck Coefficients ◽  
Nugget Growth ◽  
Simulation Results ◽  
The Impact

Abstract Resistance spot welding (RSW) of aluminum–aluminum (Al–Al) is known to be very challenging, with the asymmetric growth of the weld nugget often observed. In this article, a semicoupled electrical–thermal–mechanical finite element analysis (FEA) procedure was established to simulate the RSW of two layers of AA6022-T4 sheets using a specially designed Multi-Ring Domed (MRD) electrodes. Critical to the modeling procedure was the thermoelectric (including the Peltier, Thomson, and Seebeck effects) analyses to simulate the asymmetric nugget growth in the welding stage. Key input parameters such as the Seebeck coefficients and high-temperature flow stress curves were measured. Simulation results, experimentally validated, indicated that the newly developed procedure could successfully predict the asymmetric weld nugget growth. Simulation results also showed the Seebeck effect in the holding stage. The simulations represent the first quantitative investigation of the impact of the thermoelectric effects on resistance spot welding.

A Computational Study of the Mixture Preparation in a Direct Injection Hydrogen Engine

2014 ◽  
Author(s):  
Jerome Le Moine ◽  
P. K. Senecal ◽  
Sebastian A. Kaiser ◽  
Victor M. Salazar ◽  
Jon W. Anders ◽  
...  
Keyword(s):  
Experimental Data ◽  
Flow Field ◽  
Computational Study ◽  
Early Stage ◽  
Direct Injection ◽  
Three Dimensional ◽  
Vertical Plane ◽  
Fuel Mixture ◽  
Compression Stroke ◽  
Mixture Preparation

This paper reports the validation of a three-dimensional numerical simulation of the mixture preparation in a direct-injection hydrogen-fueled engine. Computational results from the commercial code CONVERGE are compared to the experimental data obtained from an optically accessible engine. The geometry used in the simulation is a passenger-car sized, four-stroke, spark-ignited engine. The simulation includes the geometry of the combustion chamber as well as the intake and exhaust ports. The hydrogen is supplied at 100 bar from a centrally located injector with a single-hole nozzle. The comparison between the simulation and experimental data is made on the central vertical plane. The fuel mole concentration and flow field are compared during the compression stroke at different crank angles. The comparison shows good agreement between the numerical and experimental results during the early stage of the compression stroke. The penetration of the jet and the interaction with the cylinder walls are correctly predicted. The fuel spreading is under predicted which results in differences in flow field and fuel mixture during the injection between experimental and numerical results. At the end of the injection, the fuel distribution shows some disagreement which gradually increases during the rest of the simulation.

Study on Nugget Growth in Resistance Spot Welding of Thin Aluminum A1100 Using Welding Simulation

2018 ◽  
Vol 929 ◽  
pp. 191-199
Author(s):  
Ario Sunar Baskoro ◽  
Andreas Edyanto ◽  
Muhammad Azwar Amat ◽  
Hakam Muzaki
Keyword(s):  
Weld Joint ◽  
Cycle Time ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Welding Process ◽  
Metal Plate ◽  
Weld Nugget ◽  
Welding Time ◽  
Resistance Spot ◽  
Nugget Growth

Resistance spot welding (RSW), generally which is one of the most often used to joint metal plate in the automotive and aviation industries. RSW welding process involves electrical, thermal mechanical, metallurgy, and complex surface phenomenon. Unlike the other welding processes, weld joint formation in RSW process occurs very quick (in milli-seconds) and took place between the workpieces overlap each other. Welding simulation allows visual examination of the weld joint without having to perform an expensive experiment. Weld nugget size is the most important parameter in determining the mechanical behavior of welded joints in RSW process. The quality and strength of the weld joint in RSW process is predominantly determined by the shape and size of the weld nugget. Simulation modeling of RSW process performed using ANSYS Parametric Design Language (APDL) module based on the finite element method (FEM), embedded in ANSYS Workbench. Electrical and transient-thermal interaction was developed to study the weld nugget growth on resistance spot welding of aluminum A1100 metal plate with a thickness of 0.4 mm respectively. Weld nugget diameter can be well predicted by using this simulation model from the temperature distribution during the welding process. Welding is performed by varying the weld current (1 kA and 2 kA) and the welding time for each electric current, which are start from 0.5, 1.0, and 1.5 cycle time. Nugget diameter for each of the welding parameters from the simulation modelling were 4,276 mm, 4,372 mm, 4,668 mm, 5,616 mm and 5,896 mm. Weld expulsion occurred for the specimen with welding current 2 kA and welding time 1.5 cycle time, characterized by the decreasing of the tensile-shear strength of the specimen.

A Computational Study of the Mixture Preparation in a Direct–Injection Hydrogen Engine

2015 ◽  
Vol 137 (11) ◽  
Author(s):  
Jerome Le Moine ◽  
P. K. Senecal ◽  
Sebastian A. Kaiser ◽  
Victor M. Salazar ◽  
Jon W. Anders ◽  
...  
Keyword(s):  
Experimental Data ◽  
Flow Field ◽  
Computational Study ◽  
Early Stage ◽  
Direct Injection ◽  
Three Dimensional ◽  
Vertical Plane ◽  
Fuel Mixture ◽  
Compression Stroke ◽  
Mixture Preparation

This paper reports the validation of a three-dimensional numerical simulation of the mixture preparation in a direct-injection (DI) hydrogen-fueled engine. Computational results from the commercial code CONVERGE are compared to the experimental data obtained from an optically accessible engine. The geometry used in the simulation is a passenger-car sized, four-stroke, and spark-ignited engine. The simulation includes the geometry of the combustion chamber as well as the intake and exhaust ports. The hydrogen is supplied at 100 bar from a centrally located injector with a single-hole nozzle. The comparison between the simulation and experimental data is made on the central vertical plane. The fuel mole concentration and flow field are compared during the compression stroke at different crank angles (CA). The comparison shows good agreement between the numerical and experimental results during the early stage of the compression stroke. The penetration of the jet and the interaction with the cylinder walls are correctly predicted. The fuel spreading is under predicted which results in differences in flow field and fuel mixture during the injection between experimental and numerical results. At the end of the injection, the fuel distribution shows some disagreement which gradually increases during the rest of the simulation.

scholarly journals Dissimilar spot welding of DQSK/DP600 steels: the weld-nugget growth

2016 ◽  
Vol 50 (5) ◽  
pp. 761-765 ◽  
Author(s):  
Seyed Pirooz Hoveida Marashi
Keyword(s):  
Spot Welding ◽  
Weld Nugget ◽  
Nugget Growth

Diagnostics of metal samples using the results of experimental and theoretical study of positively charged microparticles formed upon sample destruction

2018 ◽  
Vol 84 (10) ◽  
pp. 23-28
Author(s):  
D. A. Golentsov ◽  
A. G. Gulin ◽  
Vladimir A. Likhter ◽  
K. E. Ulybyshev
Keyword(s):  
Experimental Data ◽  
Early Stage ◽  
Experimental Studies ◽  
Material Model ◽  
Total Charge ◽  
Cross Sectional ◽  
Practical Applications ◽  
Mechanical And Electrical Properties ◽  
Order Of Magnitude ◽  
Using Data

Destruction of bodies is accompanied by formation of both large and microscopic fragments. Numerous experiments on the rupture of different samples show that those fragments carry a positive electric charge. his phenomenon is of interest from the viewpoint of its potential application to contactless diagnostics of the early stage of destruction of the elements in various technical devices. However, the lack of understanding the nature of this phenomenon restricts the possibility of its practical applications. Experimental studies were carried out using an apparatus that allowed direct measurements of the total charge of the microparticles formed upon sample rupture and determination of their size and quantity. The results of rupture tests of duralumin and electrical steel showed that the size of microparticles is several tens of microns, the particle charge per particle is on the order of 10–14 C, and their amount can be estimated as the ratio of the cross-sectional area of the sample at the point of discontinuity to the square of the microparticle size. A model of charge formation on the microparticles is developed proceeding from the experimental data and current concept of the electron gas in metals. The model makes it possible to determine the charge of the microparticle using data on the particle size and mechanical and electrical properties of the material. Model estimates of the total charge of particles show order-of-magnitude agreement with the experimental data.

scholarly journals Organ motion in linac-based SBRT for glottic cancer

2021 ◽  
Vol 16 (1) ◽  
Author(s):  
Annarita Perillo ◽  
Valeria Landoni ◽  
Alessia Farneti ◽  
Giuseppe Sanguineti
Keyword(s):  
Early Stage ◽  
Displacement Vector ◽  
Thyroid Cartilage ◽  
Three Dimensional ◽  
Target Volume ◽  
Glottic Cancer ◽  
Organ Motion ◽  
Delivery Times ◽  
Significant Difference ◽  
Pre Treatment

Abstract Purpose The purpose of this study is to evaluate inter- and intra-fraction organ motion as well as to quantify clinical target volume (CTV) to planning target volume (PTV) margins to be adopted in the stereotactic treatment of early stage glottic cancer. Methods and materials Stereotactic body radiotherapy (SBRT) to 36 Gy in 3 fractions was administered to 23 patients with early glottic cancer T1N0M0. Patients were irradiated with a volumetric intensity modulated arc technique delivered with 6 MV FFF energy. Each patient underwent a pre-treatment cone beam computed tomography (CBCT) to correct the setup based on the thyroid cartilage position. Imaging was repeated if displacement exceeded 2 mm in any direction. CBCT imaging was also performed after each treatment arc as well as at the end of the delivery. Swallowing was allowed only during the beam-off time between arcs. CBCT images were reviewed to evaluate inter- and intra-fraction organ motion. The relationships between selected treatment characteristics, both beam-on and delivery times as well as organ motion were investigated. Results For the population systematic (Ʃ) and random (σ) inter-fraction errors were 0.9, 1.3 and 0.6 mm and 1.1, 1.3 and 0.7 mm in the left-right (X), cranio-caudal (Y) and antero-posterior (Z) directions, respectively. From the analysis of CBCT images acquired after treatment, systematic (Ʃ) and random (σ) intra-fraction errors resulted 0.7, 1.6 and 0.7 mm and 1.0, 1.5 and 0.6 mm in the X, Y and Z directions, respectively. Margins calculated from the intra-fraction errors were 2.4, 5.1 and 2.2 mm in the X, Y and Z directions respectively. A statistically significant difference was found for the displacement in the Z direction between patients irradiated with > 2 arcs versus ≤ 2 arcs, (MW test, p = 0.038). When analyzing mean data from CBCT images for the whole treatment, a significant correlation was found between the time of delivery and the three dimensional displacement vector (r = 0.489, p = 0.055), the displacement in the Y direction (r = 0.553, p = 0.026) and the subsequent margins to be adopted (r = 0.626, p = 0.009). Finally, displacements and the subsequent margins to be adopted in Y direction were significantly greater for treatments with more than 2 arcs (MW test p = 0.037 and p = 0.019, respectively). Conclusions In the setting of controlled swallowing during treatment delivery, intra-fraction motion still needs to be taken into account when planning with estimated CTV to PTV margins of 3, 5 and 3 mm in the X, Y and Z directions, respectively. Selected treatments may require additional margins.

scholarly journals Shoulder Related Temperature Thresholds in FSSW of Aluminium Alloys

Materials ◽  
2021 ◽  
Vol 14 (16) ◽  
pp. 4375
Author(s):  
David G. Andrade ◽  
Sree Sabari ◽  
Carlos Leitão ◽  
Dulce M. Rodrigues
Keyword(s):  
Heat Generation ◽  
Process Parameters ◽  
Rotational Speed ◽  
Aluminium Alloys ◽  
Spot Welding ◽  
Base Material ◽  
Main Process ◽  
Welding Temperature ◽  
Friction Stir ◽  
Tool Diameter

Friction Stir Spot Welding (FSSW) is assumed as an environment-friendly technique, suitable for the spot welding of several materials. Nevertheless, it is consensual that the temperature control during the process is not feasible, since the exact heat generation mechanisms are still unknown. In current work, the heat generation in FSSW of aluminium alloys, was assessed by producing bead-on-plate spot welds using pinless tools. Coated and uncoated tools, with varied diameters and rotational speeds, were tested. Heat treatable (AA2017, AA6082 and AA7075) and non-heat treatable (AA5083) aluminium alloys were welded to assess any possible influence of the base material properties on heat generation. A parametric analysis enabled to establish a relationship between the process parameters and the heat generation. It was found that for rotational speeds higher than 600 rpm, the main process parameter governing the heat generation is the tool diameter. For each tool diameter, a threshold in the welding temperature was identified, which is independent of the rotational speed and of the aluminium alloy being welded. It is demonstrated that, for aluminium alloys, the temperature in FSSW may be controlled using a suitable combination of rotational speed and tool dimensions. The temperature evolution with process parameters was modelled and the model predictions were found to fit satisfactorily the experimental results.

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