scholarly journals Effect of Double Pulse Resistance Spot Welding Process on 15B22 Hot Stamped Boron Steel

Metals ◽  
2020 ◽  
Vol 10 (10) ◽  
pp. 1279
Author(s):  
Hwa-Teng Lee ◽  
Yuan-Chih Chang
Keyword(s):  
Heat Input ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Welding Process ◽  
Double Pulse ◽  
Weld Nugget ◽  
Boron Steel ◽  
Welding Parameters ◽  
Tensile Shear ◽  
Resistance Spot

Double pulse resistance spot welding process by applying a second step welding current is a new pathway to alter the mechanical properties for advanced high strength steels. Herein, the resistance spot welding (RSW) of hot stamped boron steel 15B22 by one-step and two-step welding with different welding currents is investigated. The results of the tensile–shear test, size of the weld nugget, hardness distribution, microstructure, and failure mode of different welding parameters are analyzed. The weldment of the two-step RSW with a higher heat input exhibits a lower tensile–shear load and lower fracture energy when the size of the weld nugget is large. The microstructural study reveals the appearance of a partially melted zone and sub-critical heat affected zone in the weldment where the fracture readily occurred. Thus, the two-step RSW process weakens the strength of the sample, which is attributed to the partial softening in the weldment due to the higher heat input.

The Influence of Welding Parameters on Effected the Complete for Resistance Spot Welding on Mild Steel

2011 ◽  
Vol 214 ◽  
pp. 113-117 ◽  
Author(s):  
Prachya Peasura
Keyword(s):  
Mild Steel ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Welding Process ◽  
Welding Current ◽  
Welding Parameters ◽  
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 mild steel sheet metal. The experiments with full factorial design. The factors used in this study are welding current, welding time and electrode force. 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 both of 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 and nugget size are the most welding current 10,000 amp., welding time 10 cycle and electrode force 1 kN. were tensile shear 7.13 kN. and nugget size maximum 6.75 mm. This research can bring information to the foundation in choosing the appropriate parameters to resistance spot welding process.

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.

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.

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.

Numerical simulation of weld nugget in resistance spot welding process

2020 ◽  
Vol 27 ◽  
pp. 2958-2963
Author(s):  
Abhishek Kumar ◽  
Sikta Panda ◽  
Gaurab Kumar Ghosh ◽  
Ritesh Kumar Patel
Keyword(s):  
Numerical Simulation ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Welding Process ◽  
Weld Nugget ◽  
Resistance Spot

A novel expulsion control strategy with abnormal condition adaptability for resistance spot welding

2021 ◽  
pp. 1-27
Author(s):  
Yan Shen ◽  
Yu-Jun Xia ◽  
Huan Li ◽  
Lang Zhou ◽  
Hai-Tao Pan ◽  
...  
Keyword(s):  
Control Strategy ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Welding Current ◽  
Weld Nugget ◽  
Size Difference ◽  
Welding Parameters ◽  
Low Carbon ◽  
Resistance Spot ◽  
Abnormal Condition

Abstract Welding expulsion is a common problem in Resistance Spot Welding (RSW) process, which severely impacts weld quality and surrounding facilities. Existing expulsion control strategies are ineffective for complex and changeable welding conditions. This article studied the growth relationship between weld nugget and corona bond under two abnormal conditions: edge proximity (EP) and initial sheet gaps (IG). It is testified that expulsion would occur when the nugget size exceeds the corona bond size under EP and IG conditions. Reducing the welding current before the expulsion time can increase the size difference between the corona bond and the weld nugget, thereby delay and even eliminate the occurrence of expulsion. In this way, a novel online expulsion control strategy, named short-time current regulation (STCR), is proposed through expulsion moment analysis of historical weld data. The effect of the new control strategy is verified with workpieces ranging from low carbon steel to ultra-high strength steel. Experimental results showed that STCR can effectively reduce the amount of expelled metal, decrease the indentation depth and increase the nugget diameter. The method not only works well under one specific abnormal condition, but also adapts to the transition between different welding conditions. This novel expulsion control strategy can help achieve expulsion-free RSW process in mass production without frequent manual offline optimization of welding parameters.

scholarly journals Adaptive Resistance Spot Welding Process that Reduces the Shunting Effect for Automotive High-Strength Steels

Metals ◽  
2018 ◽  
Vol 8 (10) ◽  
pp. 775 ◽  
Author(s):  
Jiyoung Yu
Keyword(s):  
Heat Input ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Welding Process ◽  
Vehicle Body ◽  
Logistic Growth ◽  
Power Curve ◽  
Resistance Spot ◽  
Welding Heat Input ◽  
Shunting Effect

Although short-pitch resistance spot welding (RSW) significantly increases vehicle body strength, its application has been limited because of the associated shunting effect. In this study, a reference-based adaptive RSW process intended to minimize the shunting effect was proposed, and a related RSW system that controls welding current and power was developed to implement the adaptive method. The proposed RSW method compensates for the heat input loss caused by the shunting effect based on the estimated weld pitch and reference data obtained under suitable welding conditions. An exponential model was developed using a unique indicator (i.e., the ratio of the adaptive welding heat input to the reference welding heat input until the reference welding power curve peak) to estimate the weld pitch. A logistic growth model was next developed based on the relationship of the nugget diameter, heat input, and weld pitch to estimate the heat input compensation. A unique strategy using power control with a modified reference power curve was applied to supply the calculated heat input compensation. The experimental results intended to validate the proposed adaptive RSW process indicated that the proposed process effectively reduced the shunting effect and produced an improved nugget shape relative to the conventional RSW process.

Properties of Resistance Spot Welded Joint between Mild Steel and Aluminum Alloy with an Interlayer of AlCu28

2014 ◽  
Vol 675-677 ◽  
pp. 15-18 ◽  
Author(s):  
Long Long Hou ◽  
Ran Feng Qiu ◽  
Hong Xin Shi ◽  
Jun Qing Guo
Keyword(s):  
Mechanical Properties ◽  
Aluminum Alloy ◽  
Mild Steel ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Welded Joint ◽  
Welding Parameters ◽  
Shear Load ◽  
Tensile Shear ◽  
Resistance Spot

Aluminum alloy A6061 and mild steel Q235 was welded using resistance spot welding with an interlayer of AlCu28. The mechanical properties of the joint were investigated; the effects of various welding parameters on nugget diameter and tensile shear load of the joints were systematically discussed. The results reveal that it is effective to weld aluminum alloy and mild steel using resistance spot welding with an interlayer of AlCu28.

Properties of Light Metal Joint Welded by Thermal Compensation Resistance Spot Welding

2011 ◽  
Vol 230-232 ◽  
pp. 1084-1088
Author(s):  
Yi Min Tu ◽  
Ran Feng Qiu ◽  
Hong Xin Shi ◽  
Hua Yu ◽  
Ke Ke Zhang
Keyword(s):  
Aluminum Alloy ◽  
Magnesium Alloy ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Light Metal ◽  
Welding Parameters ◽  
Shear Load ◽  
Thermal Compensation ◽  
Tensile Shear ◽  
Resistance Spot

A new technique of thermal compensation resistance spot welding was used to weld light metal such as aluminum alloy sheet and magnesium alloy. The effects of welding parameters on the tensile shear strength of joint and nugget diameter were investigated. The tensile shear load and nugget of the joint increased with the increasing of welding time, whereas that of the joint decreased with the increasing of electrode force. The joint with the maximum tensile shear load of approximately 5 kN was obtained at the condition of 12 kA and 11 kA welding current for aluminum alloy and magnesium alloy, respectively. The results reveal that the thermal compensation resistance spot welding is a feasible method to weld aluminum alloy and magnesium alloy..

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