2020
DOI: 10.1115/1.4048441
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Expulsion Intensity Monitoring and Modeling in Resistance Spot Welding Based on Electrode Displacement Signals

Abstract: Weld expulsion is one of the most common welding defects during resistance spot welding (RSW) process especially for high strength steels (HSS). In order to control and eventually eliminate weld expulsion in production, accurate assessment of the expulsion severity should be the first step and is urgently required. Among the existing methods, real-time monitoring of RSW-related process signals has become a promising approach to actualize the online evaluation of weld expulsion. However, the inherent correlatio… Show more

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Cited by 13 publications
(4 citation statements)
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“…Remarkably, resistance spot welding (RSW) is a critical manufacturing technology in such sector [2], [3], since its high speed and adaptability for automation render it suitable for mass production [4]. The number of RSW joints per vehicle is very high (around 5000 according to Xia et al [5]), and there can be significant variability in the quality of each of them due to the fact that RSW is a complex process [6], [7]; more precisely, the heat generated by an electrical current has to be substantial enough to promote local melting and the formation of a weld nugget at the faying interface [8], [9], while at the same time the amount of heat is influenced by the electrical conductivity…”
Section: Introductionmentioning
confidence: 99%
“…Remarkably, resistance spot welding (RSW) is a critical manufacturing technology in such sector [2], [3], since its high speed and adaptability for automation render it suitable for mass production [4]. The number of RSW joints per vehicle is very high (around 5000 according to Xia et al [5]), and there can be significant variability in the quality of each of them due to the fact that RSW is a complex process [6], [7]; more precisely, the heat generated by an electrical current has to be substantial enough to promote local melting and the formation of a weld nugget at the faying interface [8], [9], while at the same time the amount of heat is influenced by the electrical conductivity…”
Section: Introductionmentioning
confidence: 99%
“…On the other hand, for [56,61], as the monitoring setup includes pressure sensors, the feasibility may be limited to stationary applications, but this depends on the design of the welding machine. The majority of the available studies for expulsion's online assessment [81][82][83][84] based their success on the classification of features extracted from the dynamic signals of the current, voltage, and pressure. Finally, another aspect that makes online expulsion assurance a real thing is the available studies concerning cases that involve different materials and welding infrastructure.…”
Section: A Realistic Scenario For Online Quality Assessment In Produc...mentioning
confidence: 99%
“…Manufacturers in the automotive industry face an increasingly competitive environment [1]. Remarkably, resistance spot welding (RSW) is a critical manufacturing technology in such sector [2,3], since its high speed and adaptability for automation render it suitable for mass production [4].The number of RSW joints per vehicle is very high (around 5000 according to Xia et al [5]), and there can be significant variability in the quality of each of them due to the fact that RSW is a complex process [6,7]; more precisely, the heat generated by an electrical current has to be substantial enough to promote local melting and the formation of a weld nugget at the faying interface [8,9], while at the same time the amount of heat is influenced by the electrical conductivity of the materials to be joined and by their surface condition, as well as by the thermal conductivity of the electrodes that are water-cooled and act as heat sinks [9].…”
Section: Introductionmentioning
confidence: 99%