scholarly journals Resistance Spot Welding of Aluminum Alloy and Carbon Steel with Spooling Process Tapes

Metals ◽  
2019 ◽  
Vol 9 (4) ◽  
pp. 410 ◽  
Author(s):  
Seungmin Shin ◽  
Dae-Jin Park ◽  
Jiyoung Yu ◽  
Sehun Rhee
Keyword(s):  
Aluminum Alloy ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Technological Development ◽  
Welding Process ◽  
Vehicle Body ◽  
Intermetallic Compound Layer ◽  
Main Process ◽  
Resistance Spot ◽  
Grade Steel

Many lightweight materials, including aluminum alloy, magnesium alloy, and plastic, have been used for automotives. Aluminum alloy—the most commonly utilized lightweight metal—has poor resistance spot weldability owing to its inherent properties, which demand the development of welding solutions. Various welding techniques are utilized to improve the resistance spot weldability of aluminum alloy, including DeltaSpot welding. However, the technological development for welding dissimilar metals (aluminum alloy and steel) required for vehicle body assembly is still in its nascent stages. This study proposes DeltaSpot welding (a resistance spot welding process with spooling process tapes) using the alloy combination of 6000 series aluminum alloy (Al 6K32) and 440 MPa grade steel (SGARC 440). The welding characteristics of the main process parameters in DeltaSpot welding were analyzed and the weldability of the combination of the aluminum alloy, Al 6K32, and 440 MPa grade steel was evaluated. In addition, the characteristics of the intermetallic compound layer between the 440 MPa grade steel and Al 6K32 sheets were identified via scanning electron microscopy/energy dispersive X-ray spectroscopy (SEM-EDS).

Numerical and experimental analysis of heat transfer in resistance spot welding process of aluminum alloy AA5182

2020 ◽  
Vol 111 (5-6) ◽  
pp. 1671-1682
Author(s):  
Michael Piott ◽  
Alexandra Werber ◽  
Leander Schleuss ◽  
Nikolay Doynov ◽  
Ralf Ossenbrink ◽  
...  
Keyword(s):  
Heat Transfer ◽  
Aluminum Alloy ◽  
Experimental Analysis ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Welding Process ◽  
Resistance Spot

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.

scholarly journals Resistance spot welding of dissimilar alloys 1008 low carbon steel5052 aluminum alloy

2018 ◽  
Vol 8 (02) ◽  
Author(s):  
Mohammad Jameel Zedan ◽  
Qasim M. Doos
Keyword(s):  
Aluminum Alloy ◽  
Carbon Steel ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Low Carbon Steel ◽  
Welding Current ◽  
Intermetallic Compound Layer ◽  
Low Carbon ◽  
Resistance Spot ◽  
Dissimilar Alloys

The resistance spot welding is adopted to joint dissimilar alloys such as aluminum alloy 5052, and low carbon steel alloy 1008. In this work, the electrodes force 2100-2700 N, the welding current 7.5-10.5 KA, and welding time 10-20 cycle have been used. The relationships between the three parameters have been studied. The maximum tensile shear load of the aluminum alloy 5052-low carbon steel 1008 joint has been found equal to 2860 N for weld nugget diameter of 9 mm. The intermetallic compound layer (IMC) with 2-8 μm thickness with tongue-like has been appeared adjacent to the 1008 low carbon steel side, whereas a needle-shaped IMC layer adjacent to the aluminum alloy 5052 side

scholarly journals Friction Stir Resistance Spot Welding of Aluminum Alloy to Advanced High Strength Steel

2018 ◽  
Vol 140 (11) ◽  
Author(s):  
Kai Chen ◽  
Xun Liu ◽  
Jun Ni
Keyword(s):  
Aluminum Alloy ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Plastic Material ◽  
Welding Process ◽  
Electrical Current ◽  
Atomic Diffusion ◽  
Friction Stir ◽  
Resistance Spot ◽  
Welding Force

A hybrid friction stir resistance spot welding (RSW) process is applied for joining aluminum alloy 6061 to TRIP 780 steel. Compared with conventional RSW, the applied current density is lower and the welding process remains in the solid state. Compared with conventional friction stir spot welding (FSSW) process, the welding force is reduced and the dissimilar material joint strength is increased. The electrical current is applied in both a pulsed and direct form. With the equal amount of energy input, the approximately same force reduction indicates that the electro-plastic material softening effect is insignificant during FSSW process. The welding force is reduced mainly due to the resistance heating induced thermal softening of materials. With the application of electrical current, a wider aluminum flow pattern is observed in the thermo-mechanically affected zone (TMAZ) of weld cross sections and a more uniform hook is formed at the Fe/Al interface. This implies that the aluminum material flow is enhanced. Moreover, the Al composition in the Al–Fe interfacial layer is higher, which means the atomic diffusion is accelerated.

scholarly journals Short-Pulse Resistance Spot Welding of Aluminum Alloy 6016-T4 - Part 1

2021 ◽  
Vol 100 (01) ◽  
pp. 41-51
Author(s):  
ERIC SCHULZ ◽  
◽  
MATTHIAS WAGNER ◽  
HOLGER SCHUBERT ◽  
WENQI ZHANG ◽  
...  
Keyword(s):  
Aluminum Alloy ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Short Pulse ◽  
Welding Process ◽  
Welding Current ◽  
Welding Parameters ◽  
Resistance Spot ◽  
Pull Out ◽  
Welding Processes

Short-pulse welding parameters for resistance spot welding (RSW) of aluminum alloy AA6016-T4 using mediumfrequency direct current (MFDC) systems were developed to reduce the heat input required for nugget formation. Optimization of current and time parameters is critical during RSW of aluminum alloys for reducing energy requirements and avoiding weld imperfections, such as solidification cracking and expulsion, while maintaining weld quality, particularly given the high electrical and thermal conductivities of the materials. The welding time and the applied current level of the current pulse were varied systematically for thin sheets (1 mm or 0.04 in.) of AA6016-T4. The quality of the welds was evaluated by pull-out testing, ultrasound testing, and metallography techniques. Simulations of the same welding processes were performed with the finite element-based SORPAS® software. The results showed short-pulse MFDC RSW can reduce the energy required for sound welds in this alloy without requiring an increase in welding current. The simulations and experiments also showed the welding process had distinct weld nugget nucleation and growth phases.

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.

Dissimilar metals joining of steel and aluminum alloy by resistance spot welding

2014 ◽  
Vol 32 (2) ◽  
pp. 83-94 ◽  
Author(s):  
Kenji MIYAMOTO ◽  
Shigeyuki NAKAGAWA ◽  
Chika SUGI ◽  
Kenji TSUSHIMA ◽  
Shingo IWATANI ◽  
...  
Keyword(s):  
Aluminum Alloy ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Dissimilar Metals ◽  
Resistance Spot
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