Real-time measuring system design and application of thermal expansion displacement during resistance spot welding process

2005 ◽  
Author(s):  
YongBing Li ◽  
Jun Xu ◽  
GuanLong Chen ◽  
ZhongQin Lin
Keyword(s):  
Thermal Expansion ◽  
System Design ◽  
Real Time ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Welding Process ◽  
Measuring System ◽  
Resistance Spot ◽  
Design And Application

scholarly journals Analysis of the Behavior of Dynamic Resistance, Electrical Energy and Force between the Electrodes in Resistance Spot Welding Using Additive Manufacturing

Metals ◽  
2020 ◽  
Vol 10 (5) ◽  
pp. 690
Author(s):  
Márcio Batista ◽  
Valdir Furlanetto ◽  
Sérgio Duarte Brandi
Keyword(s):  
Thermal Expansion ◽  
Additive Manufacturing ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Welding Process ◽  
Electrical Energy ◽  
Dynamic Resistance ◽  
Low Carbon ◽  
Resistance Spot ◽  
Welding Spot

This work is aimed at the analysis of the dynamic resistance, electrical energy and behavior of the force between electrodes (including thermal expansion) during welding at optimized parameters, referring to the process of spot welding using additive manufacturing (AMSW). For comparative purposes, this analysis also includes the conventional resistance spot welding process (RSW). The experiments were done on low carbon-zinc-coated sheets used in the automotive industry. The results regarding the welding process using additive manufacturing (AMSW), in comparison to the conventional resistance spot welding (RSW), showed that the dynamic resistance presented a different behavior due to the collapse of the deposition at the beginning of the welding, and that a smaller magnitude of electrical energy (approximately <3.35 times) is required to produce a welding spot approved in accordance with the norm. No force of thermal expansion was observed during the passage of the current, in contrast, there was a decrease in the force between the electrodes due to the collapse of the deposition at the beginning of the welding.

scholarly journals Embedded Artificial Neuval Network-Based Real-Time Half-Wave Dynamic Resistance Estimation during the A.C. Resistance Spot Welding Process

2013 ◽  
Vol 2013 ◽  
pp. 1-7 ◽  
Author(s):  
Liang Gong ◽  
Yan Xi ◽  
Chengliang Liu
Keyword(s):  
Real Time ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Welding Process ◽  
Measuring Method ◽  
Computing System ◽  
Dynamic Resistance ◽  
Resistance Spot ◽  
Half Wave ◽  
Artificial Neural Network Ann

Online monitoring of the instantaneous resistance variation during the A.C. resistance spot welding is of paramount importance for the weld quality control. On the basis of the welding transformer circuit model, a new method is proposed to measure the transformer primary-side signal for estimating the secondary-side resistance in each 1/4 cycle. The tailored computing system ensures that the measuring method possesses a real-time computational capacity with satisfying accuracy. Since the dynamic resistance cannot be represented via an explicit function with respect to measurable parameters from the primary side of the welding transformer, an offline trained embedded artificial neural network (ANN) successfully realizes the real-time implicit function calculation or estimation. A DSP-based resistance spot welding monitoring system is developed to perform ANN computation. Experimental results indicate that the proposed method is applicable for measuring the dynamic resistance in single-phase, half-wave controlled rectifier circuits.

THERMOMECHANICAL ANALYSIS OF THE RESISTANCE SPOT-WELDING PROCESS

2018 ◽  
Vol 10 (5) ◽  
pp. 449-455 ◽  
Author(s):  
Habib Lebbal ◽  
Lahouari Boukhris ◽  
Habib Berrekia ◽  
Abdelkader Ziadi
Keyword(s):  
Resistance Spot Welding ◽  
Spot Welding ◽  
Welding Process ◽  
Thermomechanical Analysis ◽  
Resistance Spot

Analysis of Electromagnetic Inverse Model of Resistance Spot Welding

2010 ◽  
Vol 160-162 ◽  
pp. 974-979
Author(s):  
Nai Feng Fan ◽  
Zhen Luo ◽  
Yang Li ◽  
Wen Bo Xuan
Keyword(s):  
Resistance Spot Welding ◽  
Regularization Method ◽  
Spot Welding ◽  
Influence Factors ◽  
Great Influence ◽  
Welding Process ◽  
Inverse Model ◽  
Resistance Spot ◽  
Inversion Theory

Resistance spot welding (RSW) is an important welding process in modern industrial production, and the quality of welding nugget determines the strength of products to a large extent. Limited by the level of RSW quality monitor, however, RSW has rarely been applied to the fields with high welding quality requirements. Associated with the inversion theory, in this paper, an electromagnetic inverse model of RSW was established, and the analysis of influence factors, such as the layout of the probes, the discrete program and the regularization method, was implemented as well. The result shows that the layout of the probe and the regularization method has great influence on the model. When the probe is located at the y direction of x-axis or the x direction of y-axis and Conjugate Gradient method is selected, a much better outcome can be achieved.

Micro Hardness in the Welded Area at Resistance Spot Welding

2016 ◽  
Vol 1138 ◽  
pp. 153-158
Author(s):  
Mihai Boca ◽  
Gheorghe Nagit ◽  
Laurenţiu Slătineanu
Keyword(s):  
Mechanical Properties ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Graphical Representation ◽  
Welding Process ◽  
Electrical Current ◽  
Micro Hardness ◽  
Current Time ◽  
Resistance Spot ◽  
Welding Spot

The resistance spot welding process represents the welding technology used to obtain assemblies trough welded spots characterized by adequate mechanical properties. This assembly process is used mainly into the automotive, petroleum and naval industries. It is applied due to the significant advantages concerning the technology and service properties of the obtained assembly. This paper purposes a study concerning the micro hardness change of an assembly made by resistance welding spot. The entire process of plastic deformations together with the solidification step developed in the presence of the heat generated during welding process determines the mechanical characteristics of the welded spot and, of course, of the assembly obtained. In such conditions, depending on the changes developed during the welding process, the micro hardness of the welded spot varies between the fusion area (FA) and heat affected zone (HAZ). In this way, the graphical representation of the micro hardness repartition gives clues about the weakness areas which don’t correspond to the requirements. As input factors, in this study, the values of current intensity, the electrical current time and the force pressure were considered. In order to solve the proposed problem and to graphically highlight the variation of the micro hardness obtained for welded points, it was used a classical welding device and a micro hardness device analyzer. The graphical representation shows that the micro-hardness and, as a consequence, some mechanical properties changes in the specified region and in the entire mass of the welded spot changes. In this way, the structure of welded spot is characterized by a variation of the hardness in the interest areas.

Evolution of Interfacial Microstructure During Resistance Spot Welding of Cu and Al With Ni-P Coating

2021 ◽  
Author(s):  
Nannan Chen ◽  
Hongliang Wang ◽  
Jingjing Li ◽  
Vic Liu ◽  
James Schroth
Keyword(s):  
Heat Input ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Void Formation ◽  
Welding Process ◽  
Kirkendall Effect ◽  
Interfacial Microstructure ◽  
Formation Mechanisms ◽  
Elemental Distribution ◽  
Resistance Spot

Abstract Dissimilar materials of copper (Cu) to aluminum (Al) with nickel-phosphorus (Ni-P) coatings were joined using resistance spot welding. The Ni-P coatings were electroless plated on the Al surfaces to eliminate the formation of brittle Cu-Al intermetallic compounds (IMCs) at the faying interface between Cu and Al. Three welding schedules with various heat input were employed to produce different interfacial microstructure. The evolution of interfaces in terms of phase constitution, elemental distribution and defects (gaps and voids) was characterized and the formation mechanisms were elucidated. During the welding process, the bonding between Cu and Ni-P forms through solid-state diffusion, while the faster diffusion rate of Cu relative to Ni and P atoms promotes the generation of sub-micron voids. As the heat input increases, gaps at the Cu/Ni-P interface diminish accompanied by increase of sub-micron voids. A moderate schedule helps to remove the gaps and inhibits the void formation. An Al3Ni layer and nanovoids were found around the interface of Ni-P/Al. The increased heat input decreases the grain size of Al3Ni at the interface by eutectic remelting and increases the nanovoids by enhanced nanoscale Kirkendall effect.

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