Evaluation of the reliability of resistance spot welding control via on-line monitoring of dynamic resistance

Butsykin, Sergey; Gordynets, A.S.; Kiselev, A. S.; Slobodyan, Mikhail

doi:10.1007/s10845-022-01987-0

Cited by 10 publications

(3 citation statements)

References 46 publications

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“…Table 1 provides the chemical composition and mechanical properties of the steel plate and the composition of the coating. The medium frequency direct current (MFDC) resistance spot welding machine is used to weld steel plates [19], and the welding mode is a constant current mode. In order to reduce the effect of stains on the surface of the steel plate upon the welding quality, the steel plate must be mechanically and chemically cleaned before welding.…”

Section: Experimental Procedures Experimental Materials and Welding C...mentioning

confidence: 99%

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Assessing Electrode Characteristics in Continuous Resistance Spot Welding of BH 340 Steel Based on Dynamic Resistance

Zhao,

Vdonin,

Slobodyan

et al. 2023

JMMP

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The aim of this investigation is to offer a data-based scheme for predicting electrode wear in resistance spot welding. One of the major factors affecting the mechanical properties of spot welds and the variation in weld quality is electrode wear and alloying. In this study, Rogowski coils and twisted pairs attached to the top and bottom electrodes were used to obtain the welding current and the voltage between the electrodes in the welding process, thereby calculating the dynamic resistance value during the welding process. The electrode tip diameter was obtained from the pressure exerted by the upper and lower electrodes on the carbon paper when the current was cut off and was regarded as an indicator of electrode wear. By continuously welding 0.5 mm thick BH 340 steel plates until the electrode failed, the dynamic resistance signal was recorded in real time. Simultaneously, the electrode diameter after every several welds was also recorded. On this basis, the correlation between electrode tip diameter and dynamic resistance is studied. In order to quantitatively study the mapping relationship between dynamic resistance and electrode wear, 10 characteristic values were extracted from the dynamic resistance, and the stepwise regression method was used to obtain the regression formula between the characteristic values and the electrode tip diameter. Using new data to verify the effectiveness of the regression model, the acquired results display that the maximum error between the predicted value of the electrode tip diameter and the measured value obtained by the regression equation with the interactive quadratic term is 0.3 mm, and the corresponding relative error is 7.69%. When welding with a new pair of electrodes, the maximum absolute error was 0.72 mm, and the relative error of the model prediction is within 20% according to the linear regression model with interaction terms. This indicates that this regression model is barely satisfactory for monitoring electrode condition.

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Section: Experimental Procedures Experimental Materials and Welding C...mentioning

confidence: 99%

“…The other welding process parameters are listed in Table 3. All the procedures for the welding operation are based on the work carried out previously [19]. The specific waveform of the welding current is shown in Figure 3.…”

Section: Experimental Procedures Experimental Materials and Welding C...mentioning

confidence: 99%

Assessing Electrode Characteristics in Continuous Resistance Spot Welding of BH 340 Steel Based on Dynamic Resistance

Zhao,

Vdonin,

Slobodyan

et al. 2023

JMMP

Self Cite

View full text Add to dashboard Cite

show abstract

“…There have been a number of research studies carried out to investigate the effect of these parameters on nugget size and spot quality [4][5][6][7][8], as well as to optimize the parameters [9,10] and monitor the process [11][12][13][14] in order to improve spot quality. An increase of welding current and heat input increases the nugget size and joint strength for materials like stainless steel, aluminium, magnesium [15][16][17].…”

Section: Introductionmentioning

confidence: 99%

Detection of electrode misalignment and its effect on joint quality in resistance spot welding: a low-cost computer vision-based approach

Bhavsar,

Dutta,

Pal

2024

Meas. Sci. Technol.

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Electrode misalignment in resistance spot welding can be caused by poor fitting or deformation of electrode with continuous usage. This leads to asymmetric weld nugget formation, porosity and expulsion. This paper presents a novel low-cost real-time inspection system for angular misalignment using an image processing approach. The proposed solution can effectively segment the electrode tips even from the image captured at noisy industrial background such as automotive assembly line, by using a regional convolutional neural network based object identification method. The trained model has a mean average precision and recall of 99.01% and 96.6%, respectively. A series of image processing tools and mathematical operations were used to identify the edge line contours of electrode tips accurately from the detection mask, and determine the angular misalignment with a maximum deviation of less than 0.06˚. Experimental results showed that the weld nuggets exhibited porosity, shrinkage voids, and cracks when performed under angular misalignment conditions.

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Mechanical attributes and microstructural characteristics of resistance spot-welded HSLA 420 steel joints

Zhao

Vdonin

Bezgans

et al. 2023

Int J Adv Manuf Technol

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Evaluation of the reliability of resistance spot welding control via on-line monitoring of dynamic resistance

Cited by 10 publications

References 46 publications

Assessing Electrode Characteristics in Continuous Resistance Spot Welding of BH 340 Steel Based on Dynamic Resistance

Assessing Electrode Characteristics in Continuous Resistance Spot Welding of BH 340 Steel Based on Dynamic Resistance

Detection of electrode misalignment and its effect on joint quality in resistance spot welding: a low-cost computer vision-based approach

Mechanical attributes and microstructural characteristics of resistance spot-welded HSLA 420 steel joints

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