scholarly journals Effects of Surface Roughness and Force of Electrode on Resistance Spot Weldability of Aluminum 6061 Alloy

2019 ◽  
Vol 9 (19) ◽  
pp. 3958 ◽  
Author(s):  
Jo ◽  
Kim ◽  
Kang ◽  
Park ◽  
Kim
Keyword(s):  
Surface Roughness ◽  
Electrode Surface ◽  
Spot Welding ◽  
Thickness Direction ◽  
Tensile Shear Strength ◽  
Tensile Shear ◽  
Resistance Spot ◽  
Electrode Force ◽  
Effective Removal ◽  
Aluminum 6061 Alloy

The effects of electrode surface roughness and force on the resistance spot weldability and sticking of the electrode during resistance spot welding (RSW) of aluminum 6061-T6 alloy were investigated. RSW was carried out using an as-received electrode and an abraded electrode polished with sandpaper, and the nugget size and properties such as tensile shear strength and hardness of the resulting welds were investigated at two different electrode forces. In addition, a continuous RSW process was performed on the alloy to observe the effect of the electrode surface roughness on electrode sticking. When RSW was performed using the abraded electrode, which had a rough surface, the contact resistance decreased because of the effective removal of the oxide film from the surface of the aluminum alloy; consequently, the heat generated by the resistance on the surface was reduced. In addition, the growth rate of the weld nuggets formed with the abraded electrode in the thickness direction was lower than that of the nuggets formed with the as-received electrode, and the sticking of the abraded electrode was comparatively less. Also, the influence of the electrode force on the sticking of the electrode was greater in the case of the as-received electrode.

scholarly journals Optimization of Resistance Spot Welding (RSW) Parameters by using Taguchi Method

2020 ◽  
Vol 9 (3) ◽  
pp. 2795-2800
Keyword(s):  
Shear Strength ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Welding Current ◽  
Welding Parameters ◽  
Welding Time ◽  
Tensile Shear Strength ◽  
Tensile Shear ◽  
Resistance Spot ◽  
Electrode Force

This study was intended to optimize the resistance Spot Welding Parameters (RSW) of sheet metals joints. The variation parameters selected were electrode force, welding current and welding time of 1.2 mm thickness low carbon steel. The settings of process parameters were conducted according to the L9 Taguchi orthogonal array in randomized way. The optimum process parameter was then obtained by using signal to noise ratio and analyzed further on the significant level by using Analysis of Variance (ANOVA). The developed response has been found well fitted and can be effectively used for tensile shear strength prediction. The optimum parameters achieved were electrode force (2.3 kN), welding time (10 cycles) and welding current (8 kA). Based on the ANOVA, it was found that the electrode force is a vital parameter in controlling the tensile shear strength as compared to welding time and welding current.

Monitoring of Effect of Electrode Force on Resistance Spot Weld Quality Using Electrode Displacement Method

2011 ◽  
Vol 189-193 ◽  
pp. 3331-3334
Author(s):  
Xian Feng Wang ◽  
Guo Xiang Meng ◽  
Qian Ye ◽  
Jian Xia Liu ◽  
Wen Hua Xie ◽  
...  
Keyword(s):  
Shear Strength ◽  
Spot Welding ◽  
Displacement Sensor ◽  
Weld Quality ◽  
Tensile Shear Strength ◽  
Tensile Shear ◽  
Resistance Spot ◽  
Electrode Force ◽  
Electrode Displacement ◽  
The Relationship

The effect of electrode force on the weld quality of resistance spot welding monitored using electrode displacement was experimentally studied in this article. The electrode displacement was detected by the grating displacement sensor, and the maximal electrode displacement was obtained by the measurement system. The weld quality was evaluated by the tensile-shear strength of spot welds. Groups of spot welding experiments were performed under different electrode pressure, and the relationship of the maximal electrode displacement and tensile-shear strength in weld lobe was analyzed. The results showed that the relationship between electrode displacement and weld quality is not constant when the electrode force changed.

scholarly journals Resistance Spot Welding Optimization Based on Artificial Neural Network

2014 ◽  
Vol 2014 ◽  
pp. 1-6 ◽  
Author(s):  
Thongchai Arunchai ◽  
Kawin Sonthipermpoon ◽  
Phisut Apichayakul ◽  
Kreangsak Tamee
Keyword(s):  
Neural Network ◽  
Artificial Neural Network ◽  
Shear Strength ◽  
Aluminum Alloy ◽  
Parameter Optimization ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Tensile Shear Strength ◽  
Tensile Shear ◽  
Resistance Spot

Resistance Spot Welding (RSW) is processed by using aluminum alloy used in the automotive industry. The difficulty of RSW parameter setting leads to inconsistent quality between welds. The important RSW parameters are the welding current, electrode force, and welding time. An additional RSW parameter, that is, the electrical resistance of the aluminum alloy, which varies depending on the thickness of the material, is considered to be a necessary parameter. The parameters applied to the RSW process, with aluminum alloy, are sensitive to exact measurement. Parameter prediction by the use of an artificial neural network (ANN) as a tool in finding the parameter optimization was investigated. The ANN was designed and tested for predictive weld quality by using the input and output data in parameters and tensile shear strength of the aluminum alloy, respectively. The results of the tensile shear strength testing and the estimated parameter optimization are applied to the RSW process. The achieved results of the tensile shear strength output were mean squared error (MSE) and accuracy equal to 0.054 and 95%, respectively. This indicates that that the application of the ANN in welding machine control is highly successful in setting the welding parameters.

Dissimilar resistance spot welding of AISI 304 to AISI 409 stainless steels: mechanical properties and microstructural evolutions

2018 ◽  
Vol 115 (6) ◽  
pp. 610 ◽  
Author(s):  
Mehdi Safari ◽  
Hossein Mostaan ◽  
Abdoreza Ghaderi
Keyword(s):  
Stainless Steels ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Steel Sheet ◽  
Welding Current ◽  
Stainless Steel Sheet ◽  
Tensile Shear ◽  
Aisi 304 ◽  
Resistance Spot ◽  
Electrode Force

In this work, dissimilar resistance spot welding of austenitic stainless steel sheet (304 grade) and ferritic stainless steel sheet (409 grade) is studied experimentally. For this purpose, the effects of process parameters such as welding current, welding time and electrode force on tensile-shear strength of resistance spot welded joints are investigated with response surface methodology (RSM). Also, microstructural evolutions during resistance spot welding process of AISI 409 and AISI 304 stainless steels are evaluated by optical microscopy. It is concluded from results that the tensile-shear strength of spot welds is increased with increasing the welding current, welding time and electrode force. It is shown that widmanstatten ferrites have been grown in the weld metal of dissimilar resistance spot welds of AISI 304 and AISI 409 stainless steels.

Effect of Resistance Spot Welding Parameters on the Austenitic Stainless Steel 304 Grade by Using 23 Factorial Design

2011 ◽  
Vol 216 ◽  
pp. 666-670 ◽  
Author(s):  
Prachya Peasura
Keyword(s):  
Stainless Steel ◽  
Austenitic Stainless Steel ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Welding Process ◽  
Welding Current ◽  
Welding Time ◽  
Tensile Shear ◽  
Resistance Spot ◽  
Electrode Force

This research was study the effect of resistance spot welding process on physical properties. The specimen was austenitic stainless steel sheet of 1 mm. The experiments with 23 factorial design. The factors used in this study are welding current at 8,000 and 12,000 Amp, welding time at 8 and 12 cycle and electrode force were set at 1.5 and 2.5 kN. The welded specimens were tested by tensile shear testing according to JIS Z 3136: 1999 and macro structure testing according to JIS Z 3139: 1978. The result showed that the welding current, welding time and electrode force had interaction on tensile shear and nugget size at 95% confidential (P value < 0.05). Factors affecting the tensile shear are the most welding current of 12,000 amp., welding time of 8 cycle and electrode force of 2.5 kN. were tensile shear of 9.83 kN. The nugget size was maximum at 7.15 mm. on welding current of 12,000 amp., welding time of 12 cycle and electrode force of 1.5 kN This research can bring information to the foundation in choosing the appropriate parameters to resistance spot welding process.

Effect of Electrode Force on Tensile Shear and Nugget Size of Austenitic Stainless Steel Grade 304 Welds Using Resistance Spot Welding

2011 ◽  
Vol 52-54 ◽  
pp. 2176-2180
Author(s):  
Prachya Peasura
Keyword(s):  
Stainless Steel ◽  
Austenitic Stainless Steel ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Current Flow ◽  
Welding Current ◽  
P Value ◽  
Tensile Shear ◽  
Resistance Spot ◽  
Electrode Force

This research was to effect of electrode force on the tensile shear and nugget size of the resistance spot welding. The specimen was austenitic stainless steel 304 grade sheet metal 1.2 mm thickness. The electrode force are 1, 1.5, 2.0, 2.5, and 3.0 kN apply to the specimen. The replications in each treatment are 20 follow JIS Z 3136:1999 and JIS Z 3139:1978. Factor control, welding current 7 kA., time current flow 7 cycle and electrode tip diameter 6 mm. The welded specimens were tested by tensile shear testing according to JIS Z 3136: 1999, macro structure testing according to JIS Z 3139: 1978 and analysis results by using One-way ANOVA .The result showed that electrode force had affected on tensile shear and nugget size at 95% confidential (P value > 0.05). The low force induced the gab between specimen increasing then the current flow difficult to pass and both of gab between specimen and nugget seize had increase (Q=I2Rt). When the resistance increased so that fusion zone will have a high heating. It had affected to nugget size, heat affected zone and mechanical properties decreasing. The electrode forces are complete 2.5 kN. tensile shear 9.21 kN and nugget size 5.82 mm. The data can be applied to be used as process monitoring of resistance spot weld quality

Effects of Welding Time and Alloy Elements on Mechanical Properties of Aluminum/SPCC Joint Using Resistance Spot Welding

2012 ◽  
Vol 602-604 ◽  
pp. 2123-2129
Author(s):  
Nan Wang ◽  
Tomiko Yamaguchi ◽  
Kazumasa Nishio
Keyword(s):  
Shear Strength ◽  
Aluminum Alloy ◽  
Aluminum Alloys ◽  
Intermetallic Compound ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Welding Time ◽  
Tensile Shear Strength ◽  
Tensile Shear ◽  
Resistance Spot

In this study, effects of welding time and elements Mg, Si and Cu in aluminum alloys on hardness and tensile shear strength of aluminum alloys/steel joints in resistance spot welding have been investigated. The welding current was kept a constant 10.5kA and electrode force was 1kN. Welding time was increased from 0.067s up to 0.2s with a rise of 0.033s. Two intermetallic compound layers were generated at weld interfacial zones between aluminum alloys and steel during welding process, and the major phases were FeAl3 adjacent and directing to aluminum alloy and Fe2Al5 adjacent and directing to the steel. Diffusion of Si in aluminum alloy occurred at the interface, whereas the diffusion of Mg and Cu was not observed at the interface according to the EPMA analysis results. Hardness of intermetallic compound layers was 13.8GPa, which was about 12 times as much as that of the aluminum alloy. The largest tensile-shear strength was obtained on the condition of 0.134 and 0.167s welding time.

Optimization of Parameters and Research on Joint Microstructure of Resistance Spot Welding for 316 Stainless Steel

2013 ◽  
Vol 652-654 ◽  
pp. 2326-2329 ◽  
Author(s):  
Hui Liu ◽  
Xue Dong Xu ◽  
Xiao Qing Zhang
Keyword(s):  
Stainless Steel ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Welding Current ◽  
Shear Load ◽  
Welding Time ◽  
Tensile Shear ◽  
316 Stainless Steel ◽  
Resistance Spot ◽  
Electrode Force

The experimental investigations on resistance spot welding are presented for 316 stainless steel. The influence of spot welding parameters (welding time, electrode force and welding current) on the tensile shear load and the diameter of nugget have been researched, based on an orthogonal test and analysis method. The results show that welding current has significant influence on the tensile shear load and diameter of nugget, and then is electrode force, welding time in turn. The optimum parameters are as follows: welding time is 5 cycles, electrode force is 3.5KN and welding current is 5.5KA. And the maximum tensile shear force of joint is up to 13.55KN.

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