A New Approach for Robust High-Productivity Resistance Spot Welding of Aluminium

Boomer, D. R.; Hunter, John; Castle, D.

doi:10.4271/2003-01-0575

Cited by 22 publications

(19 citation statements)

References 3 publications

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“…It is generally recognised that the short life of the welding electrodes and the associated reduction in weld quality as the electrodes degrade [4,5,6] present major challenges when welding aluminium. The work previously undertaken by the University of Warwick [7,8] has proved that significant improvements in electrode life and consequently weld quality can be achieved by rigorous process control.…”

Section: Introductionmentioning

confidence: 99%

A comparison of the mechanical behaviour of self-piercing riveted and resistance spot welded aluminium sheets for the automotive industry

2010

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Abstract:The increased application of lightweight materials, such as aluminium has initiated many investigations into new joining techniques for aluminium alloys. The Resistance Spot Welding (RSW) concept for aluminium has always attracted many researchers from different organizations. Selfpiercing riveting (SPR) is the major production process used to join aluminium sheet body structures for the automotive industry. The research team at the University Of Warwick has investigated these two major joining technologies for aluminium assembly. The paper reported here gives an in depth comparison of the mechanical behavior for each joint type under different loading conditions. It covers symmetrical and asymmetrical assembly from thin gauge of 1.0mm to thick gauge of 3.0mm. The results suggest that generally RSW can provide similar strength performance to SPR with the exception of T-peel; the energy to maximum load needs be considered 'case to case' and is dependent largely on loading conditions and the failure mode particularly with respect to SPR. The spread of results for SPR is generally smaller than RSW, and the performance of SPR joints improves as the thickness increases.

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Section: Introductionmentioning

confidence: 99%

A comparison of the mechanical behaviour of self-piercing riveted and resistance spot welded aluminium sheets for the automotive industry

2010

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“…More recent material, equipment and welding process developments to extend electrode-life, enhance weld quality and reduce power consumption are making this process increasingly attractive to automakers [1,12] . RSW is able to join multilayer aluminium stacks comprising individual sheets from 0.9 mm to 4 mm in a wide range of alloys as shown in Figure 1.…”

Section: Resistance Spot Weldingmentioning

confidence: 99%

“…Recent work at Warwick University following on from tests at Alcan International's Banbury Research Laboratories [1] has shown that an electrode-life in excess of 10,000 welds can be achieved by adopting regular electrode cleaning between components to keep the electrodes in good condition. The motivation for maintaining the electrode condition is that high quality welds can be produced consistently, providing the electrode has a minimal level of damage [1] . The typical cost for a pair of copper zirconium electrodes is $2.…”

Section: Consumablesmentioning

confidence: 99%

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Comparison of Self-Pierce Riveting, Resistance Spot Welding and Spot Friction Joining for Aluminium Automotive Sheet

Briskham¹,

Blundell²,

Han³

et al. 2006

SAE Technical Paper Series

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This work compares three aluminium sheet joining processes to determine their capability, efficiency and cost for mass production applications in automotive structures and closures. The joining processes investigated are Resistance Spot Welding (RSW), SelfPierce Riveting (SPR) and Spot Friction Joining (SFJ). Quantitative comparisons have been made on the basis of tensile strength (shear and peel), process time, equipment price and running cost.RSW is the most commonly employed joining method for steel sheet in the automotive industry. Its principle benefits are high speed and low cost operation, plus the ability to weld a wide range of joint configurations with the same gun. The main process limitations for aluminium are weld consistency and electrode-life, though recent work has shown that both of these can be largely overcome with regular electrode polishing [1,2]

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“…Few researchers [8][9][10] 12) materials and for weld bonding 11) . Welding force is more influencing factor for nugget formation rather than weld time which is showing in Fig.…”

Section: Introductionmentioning

confidence: 99%

A Review on Al-Al/Al-Steel Resistance Spot Welding Technologies for Light Weight Vehicles

Saha¹,

Park²

2011

Journal of Welding and Joining

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A New Approach for Robust High-Productivity Resistance Spot Welding of Aluminium

Cited by 22 publications

References 3 publications

A comparison of the mechanical behaviour of self-piercing riveted and resistance spot welded aluminium sheets for the automotive industry

A comparison of the mechanical behaviour of self-piercing riveted and resistance spot welded aluminium sheets for the automotive industry

Comparison of Self-Pierce Riveting, Resistance Spot Welding and Spot Friction Joining for Aluminium Automotive Sheet

A Review on Al-Al/Al-Steel Resistance Spot Welding Technologies for Light Weight Vehicles

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