Comparison of Weldability Misalignment between Rivets and Electrodes in Aluminum/Steel Resistance Element Welding

Jun, Hyun-Uk; Kim, Jae Won; Kim, Jae‐Hun; Lee, Kwang-Weon; Cheon, Joo-Yong; Ji, Changwook

doi:10.5781/jwj.2021.39.1.6

Cited by 6 publications

(2 citation statements)

References 10 publications

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“…The REW joints for shear tests indicated an 18.5% higher peak load than the SPR joints. The effect of weld mechanical properties and the failure mode on the distance of misalignment that occurs during REW process was investigated by Jun et al 64) . It seems that differences exist in the tensile shear strength, cross tension strength, ductility ratio and failure mode based on the distance of misalignment.…”

Section: Mechanical Analysesmentioning

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

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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.

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Section: Mechanical Analysesmentioning

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

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“…Without correct electrode placement, misalignment may occur between the electrode and the rivet. If welding proceeds in a misaligned state, a part of the current flows between the aluminum alloy and the steel material around the rivet, resulting in an unstable weld [18].…”

mentioning

confidence: 99%

Misalignment monitoring between electrodes and a rivet in a three-sheet resistance element welding-based dynamic resistance

Kim¹,

Jo²,

Lee³

et al. 2023

Preprint

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Recently, resistance element welding (REW), a method for welding dissimilar materials is gaining popularity in the automobile industry. However, in a three-sheet REW process, in which a rivet is inserted into the middle sheet, stable welding quality cannot be guaranteed because the alignment of the rivet and electrodes cannot be visually inspected. In this study, the three-sheet REW of SPFC590 (structural steel), SABC1470 (high-strength steel), and Al6061 (aluminum alloy) was investigated. The welding quality was evaluated at an increasing misalignment, and it was compared to that of a 0-mm misalignment distance. The welding quality was significantly reduced from a 6-mm misalignment distance. The pre-contact process, which is designed for predicting misalignment, was applied prior to the actual REW process. The dynamic resistance waveform in the pre-contact process was significantly different at each misalignment distance condition because of the difference in each alignment with electrodes and workpieces. The features extracted from the dynamic resistance waveforms were applied to a deep neural network (DNN) model to monitor the misalignment between electrodes and a rivet. Because the weld quality (weld nugget diameter) was not satisfactory at distances greater than 6 mm, the threshold value of the misalignment distance was set as 6 mm. A neural network that can predict the state of the misalignment between electrodes and a rivet was designed and trained, and the misalignment was predicted with 100% accuracy from DNN model.

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Misalignment monitoring between electrodes and a rivet in three-sheet resistance element welding based on dynamic resistance

Kim,

Jo,

Lee

et al. 2023

Int J Adv Manuf Technol

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Comparison of Weldability Misalignment between Rivets and Electrodes in Aluminum/Steel Resistance Element Welding

Cited by 6 publications

References 10 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

Misalignment monitoring between electrodes and a rivet in a three-sheet resistance element welding-based dynamic resistance

Misalignment monitoring between electrodes and a rivet in three-sheet resistance element welding based on dynamic resistance

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