A comparative study on resistance spot and laser beam spot welding of ultra-high strength steel for automotive applications

Rajalingam, Paluchamy; Rajakumar, Selvarajan; Sonar, Tushar; Kavitha, Subramanian

doi:10.1016/j.ijlmm.2024.04.001

International Journal of Lightweight Materials and Manufacture

2024

DOI: 10.1016/j.ijlmm.2024.04.001

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A comparative study on resistance spot and laser beam spot welding of ultra-high strength steel for automotive applications

Paluchamy Rajalingam,

Selvarajan Rajakumar,

Tushar Sonar

et al.

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2024

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Cited by 3 publications

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Cold spray processing of AA2024/Al2O3 coating on magnesium AZ31B alloy: Process parameters optimization, microstructure and adhesive strength performance of coating

Mohankumar,

Thirumalaikumarasamy,

Sonar

et al. 2024

International Journal of Lightweight Materials and Manufacture

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Cold spray processing of AA2024/Al2O3 coating on magnesium AZ31B alloy: Process parameters optimization, microstructure and adhesive strength performance of coating

Mohankumar,

Thirumalaikumarasamy,

Sonar

et al. 2024

International Journal of Lightweight Materials and Manufacture

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Enhancing Friction Stir Spot Welding of Al 5754 and Al 6111 Joints Using Taguchi’s Technique

Gowda,

R.,

B. E.

et al. 2024

Journal of Engineering

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The present study investigates the impact of varying process parameters on the mechanical properties of friction stir spot welding (FSSW) joints involving Al 5754 and Al 6111. Taguchi’s L16 design of experiment approach was employed to conduct experiments and optimize the process parameters. Key parameters, including tool pin profile, dwell time (5–30 sec), rotating speed (250–1400 rpm), and plunge depth (1.5–1.8 mm), were systematically considered. The results indicated that the optimized welding conditions for attaining higher tensile‐shear strength are a spindle speed of 1400 rpm, dwell time of 10 sec, plunge depth of 1.7 mm, and a tool pin profile of a triangular pyramid. As for bending strength, the optimal conditions are a spindle speed of 250 rpm, dwell time of 30 sec, plunge depth of 1.8 mm, and a tool pin profile of a square pyramid, representing higher bending strength. The analysis of variance technique revealed that the tool pin profile and plunge depth significantly influenced the tensile‐shear strength and bending strength of the developed FSSW joint, respectively. Regression analysis was employed to formulate mathematical models predicting tensile and bending strength, and the predicted values closely matched experimental results with 80% accuracy.

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Analysis of the Microstructure and Mechanical Performance of Resistance Spot-Welding of Ti6Al4V to DP600 Steel Using Copper/Gold Cold-Sprayed Interlayers

Szwajka,

Zielińska-Szwajka,

Szewczyk

et al. 2024

Materials

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In this article, an attempt was made to join DP600 steel and Ti6Al4V titanium alloy sheets by resistance spot-welding (RSW) using an interlayer in the form of Cu and Au layers fabricated through the cold-spraying process. The welded joints obtained by RSW without an interlayer were also considered. The influence of Cu and Au as an interlayer on the resulting microstructure as well as mechanical properties (shear force and microhardness) of the joints were determined. A typical type of failure of Ti6Al4V/DP600 joints produced without the use of an interlayer is brittle fracture. The microstructure of the resulting joint consisted mainly of the intermetallic phases FeTi and Fe2Ti. The microstructure of the Ti6Al4V/Au/DP600 joint contained the intermetallic phases Ti3Au, TiAu, and TiAu4. The intermetallic phases TiCu and FeCu were found in the microstructure of the Ti6Al4V/Cu/DP600 joint. The maximum tensile/shear stress was 109.46 MPa, which is more than three times higher than for a welded joint fabricated without the use of Cu or Au interlayers. It has been observed that some alloying elements, such as Fe, can lower the martensitic transformation temperature, and some, such as Au, can increase the martensitic transformation temperature.

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A comparative study on resistance spot and laser beam spot welding of ultra-high strength steel for automotive applications

Cited by 3 publications

References 52 publications

Cold spray processing of AA2024/Al2O3 coating on magnesium AZ31B alloy: Process parameters optimization, microstructure and adhesive strength performance of coating

Cold spray processing of AA2024/Al2O3 coating on magnesium AZ31B alloy: Process parameters optimization, microstructure and adhesive strength performance of coating

Enhancing Friction Stir Spot Welding of Al 5754 and Al 6111 Joints Using Taguchi’s Technique

Analysis of the Microstructure and Mechanical Performance of Resistance Spot-Welding of Ti6Al4V to DP600 Steel Using Copper/Gold Cold-Sprayed Interlayers

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