Digital twin for the transient temperature prediction during coaxial one-side resistance spot welding of Al5052/CFRP

2021 ◽  
pp. 1-20
Author(s):  
Sendong Ren ◽  
Yunwu Ma ◽  
Ninshu Ma ◽  
Qian Chen ◽  
Haiyuan Wu
Keyword(s):  
Big Data ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Welding Parameters ◽  
Transient Temperature ◽  
Fe Model ◽  
Digital Twin ◽  
Resistance Spot ◽  
Side Resistance ◽  
Process Database

Abstract In the present research, a digital twin of coaxial one-side resistance spot welding (COS-RSW) was established for the real-time prediction of transient temperature field. A 3D model of COS-RSW joint was developed based on the in-house finite element (FE) code JWRIAN-SPOT. The experimental verified FE model was employed to generate the big data of temperature of COS-RSW process. Multiple dimension interpolation was applied to process database and output prediction. The FE model can predict the thermal cycle on COS-RSW joints under different parameter couples. The interpolation effect of individual welding parameters was discussed and a power weight judgement for welding time was essential to ensure accuracy. With the support of big data, the digital twin can provide visualization prediction of COS-RSW within 10 seconds, whereas numerical modelling needs at least 1 hour. The proposed application of digital twin has potential to improve the efficiency of process optimization in engineering.

Single-Side Resistance Spot Welding Process for Joining Pipes and Sheets

2013 ◽  
Vol 7 (1) ◽  
pp. 114-119 ◽  
Author(s):  
Hitomi Nishibata ◽  
◽  
Shota Kikuchi ◽  
Manabu Fukumoto ◽  
Masato Uchihara
Keyword(s):  
Resistance Spot Welding ◽  
Spot Welding ◽  
Numerical Study ◽  
Welding Process ◽  
Welding Parameters ◽  
Resistance Spot ◽  
Welding Technology ◽  
Single Side ◽  
Side Resistance ◽  
Nugget Growth

This paper describes a Single-Side resistance Spot Welding (SSSW) process which is expected to be a productive welding technology for the joining of stamped sheet panels to hollow parts for auto bodies. To obtain guidelines for making a sound weld with the SSSW process, the effects of welding parameters and the alignment of specimens on nugget growth are investigated experimentally. In addition, a numerical study is carried out to discuss the mechanism of nugget growth in the SSSW process.

Development of FEA-ANN integrated approach for process optimization of coaxial one-side resistance spot welding of Al5052 and CFRP

2021 ◽  
pp. 1-31
Author(s):  
Sendong Ren ◽  
Yunwu MA ◽  
Ninshu Ma
Keyword(s):  
Finite Element ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Lap Joints ◽  
Multitask Learning ◽  
Maximum Temperature ◽  
Process Window ◽  
Welding Parameters ◽  
Resistance Spot ◽  
Side Resistance

Abstract Coaxial one-side resistance spot welding (COS-RSW) is a newly developed process for joining metals and composites. In the present study, AL5052 and carbon-fiber-reinforced plastic (CFRP) lap joints were fabricated via COS-RSW. The welding process was modeled numerically using an in-house finite element code called JWRIAN. Single lap shear tests were performed to evaluate the joining strength. The molten zone diameter was defined and measured experimentally to verify the numerical model. An artificial neural network (ANN) was established based on multitask learning, and its training dataset was prepared via finite element analysis (FEA). The well-trained ANN was employed to generate a process window for the COS-RSW. Results demonstrated that the FEA could accurately reproduce the COS-RSW process, which served as an efficient tool for generating a process dataset without performing experiments. The ANN performed multitask learning well and predicted the welding output effectively. Furthermore, an index representing the average value of the maximum temperature in the molten interface of CFRP, was adopted to evaluate the contribution of the integral interface temperature field to the bonding strength qualitatively. An optimal value, which was close to the CFRP decomposition temperature of 340 °C, was obtained, and it exhibited an excellent correlation with higher bonding strengths. The process window provided welding parameters directly to yield the desired results.

scholarly journals 3-D modelling of the coaxial one-side resistance spot welding of AL5052/CFRP dissimilar material

2021 ◽  
Vol 68 ◽  
pp. 940-950
Author(s):  
Sendong Ren ◽  
Yunwu Ma ◽  
Ninshu Ma ◽  
Shuhei Saeki ◽  
Yoshiaki Iwamoto
Keyword(s):  
Resistance Spot Welding ◽  
Spot Welding ◽  
Dissimilar Material ◽  
Resistance Spot ◽  
Side Resistance

scholarly journals Optimization on Spot Weld Parameters in Resistance Spot Welding Process on AISI 304

2021 ◽  
Vol 11 (3) ◽  
pp. 181-185
Author(s):  
Amit Hazari ◽  
Rith Saha ◽  
Bidisha Ghosh ◽  
Debraj Sengupta ◽  
Sayan Sarkar ◽  
...  
Keyword(s):  
Resistance Spot Welding ◽  
Spot Welding ◽  
Welding Process ◽  
Welding Current ◽  
Electrical Current ◽  
Industrial Applications ◽  
Spot Weld ◽  
Welding Parameters ◽  
Resistance Spot ◽  
Weld Time

The spot welding procedure is used in a variety of industrial applications. The most critical elements influencing welding quality, productivity, and cost are the spot welding parameters. This research examines the effect of welding factors such as welding current and welding time on the strength of various welding joint designs. Resistance spot welding (RSW) is used in the automotive industry for manufacturing. This research focused on the optimization of process parameters for resistance spot welding (RSW), as well as the tensile testing and spot weld diameter. The goals of this analysis are to comprehend the physics of the process and to demonstrate the effect of electrical current, weld time, and material type on the resistance spot welding process.

scholarly journals Effect of Resistance Spot Welding Parameters on AA1100 Aluminum Alloy and SGACD Zinc coated Lap Joint Properties

2015 ◽  
Vol 3 (1) ◽  
pp. 153-160 ◽  
Author(s):  
Sakchai Chantasri ◽  
Pramote Poonnayom ◽  
Jesada Kaewwichit ◽  
Waraporn Roybang ◽  
Kittipong Kimapong
Keyword(s):  
Aluminum Alloy ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Welding Parameters ◽  
Lap Joint ◽  
Resistance Spot ◽  
Joint Properties ◽  
Aa1100 Aluminum Alloy

scholarly journals One-Sided Resistance Spot Welding of Plastic-Metal Hybrid Joints - Characterization of the Joining Zone

2019 ◽  
Vol 809 ◽  
pp. 183-189
Author(s):  
Konstantin Szallies ◽  
Michael Friedmann ◽  
Martin Bielenin ◽  
Jean Pierre Bergmann
Keyword(s):  
Resistance Spot Welding ◽  
Spot Welding ◽  
Welding Parameters ◽  
Zone Formation ◽  
Resistance Spot ◽  
Plastic Metal ◽  
Coaxial Electrode ◽  
Polymer Metal ◽  
Set Up ◽  
The Impact

Polymer-metal-hybrid components show a high potential regarding to lightweight applications. In particular, due to their fundamental differences in chemical and physical properties, new approaches must be developed for common industrial joining processes. In this study a new approach in order to characterize the joining zone formation for thermal direct joining based on resistance spot welding is reported. The feasibility of joining in half-section set-up using a coaxial electrode arrangement was investigated. The impact of the welding parameters on the joining zone formation was investigated. The parameters influencing the melting layer formation were pointed out.

scholarly journals JOINING THE COMBINATION OF AHSS STEEL AND HSLA STEEL BY RESISTANCE SPOT WELDING

2013 ◽  
Vol 7 (2) ◽  
pp. 75-78 ◽  
Author(s):  
Ľuboš Kaščák ◽  
Emil Spišák ◽  
Ivan Gajdoš
Keyword(s):  
Fuel Consumption ◽  
Welded Joints ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
High Strength ◽  
Quality Analysis ◽  
Vehicle Body ◽  
Welding Parameters ◽  
Resistance Spot ◽  
Ahss Steel

Abstract The paper deals with the optimization of parameters of resistance spot welding and quality analysis of welded joints made by combination of galvanized Advanced High Strength Steel and High Strength Low Alloy steel. It is an advanced material combination utilized in automotive industry to reduce weight of the vehicle body and consequently lowering the fuel consumption to achieve the lowest possible fuel consumption, high active and passive safety of passengers while decreasing the amount of emission. The quality of welded joints was evaluated by destructive tests and non-destructive tests. The shear tensile test according to STN 05 1122 standard was used. Some samples were prepared for metallographic analysis, where the influence of the welding parameters on the structure of welded joint and occurrence of pores in the weld metal caused by evaporation of zinc from the coating was observed.

Effects of welding parameters and surface pretreatments on resistance spot welding of AZ31B Mg alloy

2010 ◽  
Vol 16 (6) ◽  
pp. 967-974 ◽  
Author(s):  
Shiquan Zhou ◽  
Lei Liu ◽  
Jae Pil Jung ◽  
Mok-Young Lee ◽  
Y. Norman Zhou
Keyword(s):  
Resistance Spot Welding ◽  
Spot Welding ◽  
Mg Alloy ◽  
Welding Parameters ◽  
Resistance Spot
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