Dynamic resistance signal–based wear monitoring of resistance spot welding electrodes

Zhao, Dawei; Vdonin, Nikita; Slobodyan, Mikhail; Butsykin, Sergey; Kiselev, Alexey; Gordynets, Anton; Wang, Yuanxun

doi:10.1007/s00170-024-13993-y

Int J Adv Manuf Technol

2024

DOI: 10.1007/s00170-024-13993-y

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Dynamic resistance signal–based wear monitoring of resistance spot welding electrodes

Dawei Zhao,

Nikita Vdonin,

Mikhail Slobodyan

et al.

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Cited by 3 publications

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Frequency domain signal analysis based index for expulsion quantification in resistance spot welding

Antal,

Razza,

De Maddis

2024

Int J Adv Manuf Technol

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Frequency domain signal analysis based index for expulsion quantification in resistance spot welding

Antal,

Razza,

De Maddis

2024

Int J Adv Manuf Technol

View full text Add to dashboard Cite

Using dynamic resistance to predict electrode surface degradation in resistance spot welding of 5182 aluminum alloy

Nikitin,

Turabov,

Ermilova

et al. 2024

Weld World

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In this study, the correlation between dynamic resistance during the first 10 ms of welding time and the electrode surface condition in resistance spot welding of 5182 aluminum alloy has been investigated. The electrode surface rapidly degrades due to contamination and morphological changes, adversely affecting the weld spot surface. The accumulation of Cu-Al intermetallic phases on the electrode surface alters its roughness, leading to variations in dynamic resistance. By analyzing this correlation, optimal electrode milling intervals were identified to extend electrode life. This work focused on detecting crater formation on the electrode surface through dynamic resistance monitoring. The results indicate that resistance measurements provide a reliable approach for evaluating electrode wear, optimizing maintenance schedules, and reducing material removal during milling.

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Derivation of Analytical Expressions for Fast Calculation of Resistance Spot Welding System Currents

Brezovnik,

Ritonja

2024

Mathematics

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The paper deals with the dynamics of a resistance spot welding system. At the core of this system is a transformer, which is powered on the primary side by a pulse-width modulated inverter and has a full-wave output rectifier on the secondary side that provides a direct welding current. The entire system is nonlinear, due to magnetic hysteresis and electronics. The electronics prevent the current from flowing in all parts of the welding transformer at separate time intervals during the voltage supply period; therefore, not all the parameters affect the dynamic of currents and voltages all the time so the system is also time-variant. To design a high-performance welding system and to predict the maximum possible welding current at a specific load, it is necessary to know the welding and primary currents. The leakage inductances of the system can reduce the maximum welding current significantly at higher frequencies and the same load. There are several methods to determine these currents, each with its drawbacks. Measurements are time-consuming, using professional software is expensive and requires time to learn and free open-source software has many limitations and does not guarantee the correctness of the results. The article presents a new, fourth option—a theoretical derivation of analytical expressions that facilitate straightforward and rapid calculation of the welding and primary currents of the resistance spot welding system with symmetrical secondary branches. The derivation of the mathematical expressions is based on the equivalent circuits that describe the system in different operating states. The results of the numerical simulations confirmed the derived expressions completely.

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Dynamic resistance signal–based wear monitoring of resistance spot welding electrodes

Cited by 3 publications

References 59 publications

Frequency domain signal analysis based index for expulsion quantification in resistance spot welding

Frequency domain signal analysis based index for expulsion quantification in resistance spot welding

Using dynamic resistance to predict electrode surface degradation in resistance spot welding of 5182 aluminum alloy

Derivation of Analytical Expressions for Fast Calculation of Resistance Spot Welding System Currents

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