Analysing resistance element welding with upset auxiliary joining steel-elements under shear load

Meinhardt, M.; Endres, Martin; Graf, M.; Lechner, Michael; Merklein, Marion

doi:10.1016/j.promfg.2019.02.145

Cited by 10 publications

(10 citation statements)

References 9 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…However, SPR technology for joining of these advanced light materials remains a challenge as these materials often lack a good combination of high strength and ductility to resist the large plastic deformation. By combining the mechanical(riveting) and thermal (welding) joining principles, a new joining technology, called REW has recently been developed as a fusion joining technology 18) . The developed technique was reported to address the challenges of joining Al alloys to steels.…”

Section: Introductionmentioning

confidence: 99%

An Overview of Resistance Element Welding with Focus on Mechanical and Microstructure Joint and Optimization in Automotive Metal Joints

Shim

Park²,

Kim

2023

J Weld Join

View full text Add to dashboard Cite

As lightweight automotive structures improve fuel efficiency and reduce carbon dioxide emission, they have garnered extensive attention. Vehicle mass reduction, which is a key problem for next generation eco-friendly vehicles, can significantly increase mileage. Hence, industries have committed to replace conventional materials with lightweight materials, such as advanced high strength steel. Additionally, automotive industries are hindered by challenges in the field of joining technology. A novel welding technology called resistance element welding (REW), which is an appropriate thermal-based joining method, was developed recently for joining hybrid materials with other structural steel grades. In this study, the state of the art joining and the process characteristics for dissimilar metal joints have been presented because related studies show limited investigation in this area. Following by the state of them, the principal and welding quality of REW, experimentally and numerically, are reported to give comprehensive information on the current practices and research interest related to technologies. Finally, extensive work was concentrated on portional joining optimization techniques to improve different materials.

show abstract

Section: Introductionmentioning

confidence: 99%

An Overview of Resistance Element Welding with Focus on Mechanical and Microstructure Joint and Optimization in Automotive Metal Joints

Shim

Park²,

Kim

2023

J Weld Join

View full text Add to dashboard Cite

show abstract

“…Furthermore, Manladan et al 24 showed the applicability of the REW technique to connect magnesium alloy with stainless steel. An investigation of REW with upset steel rivet in aluminum alloy sheets of different thicknesses reported that as the thickness increased to 1.1 mm, the tensile-shear strength increased to 4500 N. 25 In this study, we have used countersunk holes and steel rivets to join the dissimilar metals 5052 aluminum alloy and DP780 dual-phase steel, which are used in the automotive industry for lightweight materials. It is also important to note that this process differs from other REW processes.…”

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Microstructural and mechanical characterization of steel-DP780/Al-5052 joints formed using resistance element welding with concealed rivet cover

Cai

Wang

et al. 2022

Composites and Advanced Materials

View full text Add to dashboard Cite

Resistance element welding (REW) with a concealed rivet cover (Q235) was used to join steel-DP780 and Al-5052. The macroscopic morphology and the microstructure were observed using optical microscopy and scanning electron microscopy. The mechanical properties of the joint were also tested. The results show that the intermetallic compound (IMC) formed at the Q235/Al interface is FeAl3, while the IMCs formed at the DP780/Al interface are Fe2Al5 and FeAl3. The welding current has a significant influence on the nugget size, peak load, average hardness of aluminum heat-affected zone, and the bearing area of the aluminum plate. There are three fracture models of the countersunk rivet REW joint under a tensile-shear force: the interface failure fracture model, the fusion pullout failure fracture model, and the heat-affected zone failure fracture model. At a welding current of 18 kA, the nugget pullout failure mode is observed, and the best mechanical properties of the joint are obtained. The shear resistance of the joint can reach up to 5712 N.

show abstract

“…According to the work in [8], this can be attributed to the linear increase in the cross-sectional area for force transmission. Another process that can be mentioned in the context of joining dissimilar metals is resistance welding with an upset auxiliary element [11]. Here, a prepunched aluminium sheet with embossed edges is joined with a steel sheet using a steel auxiliary element.…”

Section: Introductionmentioning

confidence: 99%

Experimental Study on Joining by Forming of HCT590X + Z and EN-AW 6014 Sheets Using Cold Extruded Pin Structures

Römisch

Kraus

Merklein

2021

JMMP

Self Cite

View full text Add to dashboard Cite

Due to stricter emission targets in the mobility sector and the resulting trend towards lightweight construction in order to reduce weight and consequently emissions, multi-material systems that allow a material to be placed in the right quantity and in the right place are becoming increasingly important. One major challenge that is holding back the rapid and widespread use of multi-material systems is the lack of adequate joining processes that are suitable for joining dissimilar materials. Joining processes without auxiliary elements have the advantage of a reduced assembly effort and no additional added weight. Conventional joining processes without auxiliary elements, such as welding, clinching, or the use of adhesives, reach their limits due to different mechanical properties and chemical incompatibilities. A process with potential in the field of joining dissimilar materials is joining without an auxiliary element using pin structures. However, current pin manufacturing processes are mostly time-consuming or can only be integrated barely into existing industrial manufacturing processes due to their specific properties. For this reason, the present work investigates the production of single- and multi-pin structures from high-strength dual-phase steel HCT590X + Z (DP600, t0 = 1.5 mm) by cold extrusion directly out of the sheet metal. These structures are subsequently joined with an aluminium sheet (EN AW-6014-T4, t0 = 1.5 mm) by direct pin pressing. For a quantitative evaluation of the joint quality, tensile shear tests are carried out and the influence of different pin heights, pin number, and pin arrangements, as well as different joining strategies on the joint strength is experimentally evaluated. It is proven that a single pin structure with a diameter of 1.5 mm and an average height of 1.86 mm achieves a maximum tensile shear force of 1025 N. The results reveal that the formation of a form-fit during direct pin pressing is essential for the joint strength. By increasing the number of pins, a linear increase in force could be demonstrated, which is independent of the arrangement of the pin structures.

show abstract

Analysing resistance element welding with upset auxiliary joining steel-elements under shear load

Cited by 10 publications

References 9 publications

An Overview of Resistance Element Welding with Focus on Mechanical and Microstructure Joint and Optimization in Automotive Metal Joints

An Overview of Resistance Element Welding with Focus on Mechanical and Microstructure Joint and Optimization in Automotive Metal Joints

Microstructural and mechanical characterization of steel-DP780/Al-5052 joints formed using resistance element welding with concealed rivet cover

Experimental Study on Joining by Forming of HCT590X + Z and EN-AW 6014 Sheets Using Cold Extruded Pin Structures

Contact Info

Product

Resources

About