Analysis of workpiece magnetisation on liquid nugget during resistance spot welding

Abstract

This paper investigates the effect of workpiece magnetisation on the magnetic flux density and nugget shape during resistance spot welding (RSW) process. To this end, this paper analyses the magnetisation process of ferromagnetic workpieces. The magnetisation was calculated by the equivalent surface current. The effect of magnetisation on the nugget shape was studied for RSW of steel and a specially designed aluminium workpiece. The results show that the magnetisation of ferromagnetic workpieces will increase the dimensions of the weld nugget in the thickness direction. The magnetic flux density induced by workpiece magnetisation and that induced by welding current have the same order of magnitude (10 21 T). This indicates that the magnetisation of ferromagnetic workpiece is an important source of magnetic force acting on liquid nugget. Therefore, it should not be ignored in studying the physics of RSW process, especially for the fluid flow in RSW of ferromagnetic materials.