Image analysis of electrode degradation in resistance spot welding of aluminium

Peng, Jianchao; Fukumoto, Satoshi; Brown, Lyndon J.; Norman, Zhou

doi:10.1179/136217104225012256

Cited by 66 publications

(32 citation statements)

References 5 publications

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“…The reason for these problems is ascribed to electrode pitting which, for a given set of welding condition, is the most influential characteristic on nugget quality and joint strength ( Ref 4,5,7,8). Unlike steel, the main source of heat during RSW of aluminum alloys is the electrical contact resistance at the interfaces, but not the bulk resistance of the worksheet (Ref [8][9][10].…”

Section: Introductionmentioning

confidence: 99%

Some Tribological Influences on the Electrode-Worksheet Interface During Resistance Spot Welding of Aluminum Alloys

Rashid

2010

J. of Materi Eng and Perform

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In this study, the effect of worksheet surface characteristics on the electrical contact resistance of electrode-worksheet interface during resistance spot welding of aluminum alloy (AA5182) was discussed. The electrical contact resistance was influenced by both the oxide layer and surface roughness of the worksheet. However, the effect of oxide layer was more dominant, and the effect of surface roughness was likely to be linked with the damaging of oxide layer and not the contact area. The oxide layer on AA5182 was non-uniform with Mg-rich small spots dispersed on the surface. Grinding and scratching the worksheet surface was effective in reducing the oxide layer thickness and, hence, reduced the electrical contact resistance. It was observed that the surfaces with higher electrical contact resistances at this interface showed faster pitting rate of electrode. The study also suggested that the static electrical contact resistance measured before resistance spot welding could be useful for predicting materials likely behavior during the actual resistance spot welding process of AA5182.

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Section: Introductionmentioning

confidence: 99%

Some Tribological Influences on the Electrode-Worksheet Interface During Resistance Spot Welding of Aluminum Alloys

Rashid

2010

J. of Materi Eng and Perform

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“…[1] Although widely used to weld steel sheet, resistance spot welding (RSW) is more difficult to apply to light alloys because of their high conductivity, low strength at elevated temperature, and tendency to degrade the electrodes. [2,3] Furthermore, alternative point joining processes like self-piercing rivets [4][5][6] have high consumable costs. FSSW has already been applied successfully in automotive manufacturing by the Mazda Motor Corporation, which claims large energy and capital investment gains compared with RSW (~90 pct energy savings and 40 pct investment reduction [1] ).…”

Section: Introductionmentioning

confidence: 99%

Material Interactions in a Novel Pinless Tool Approach to Friction Stir Spot Welding Thin Aluminum Sheet

Bakavos

Chen

Babout

et al. 2010

Metall Mater Trans A

117

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The requirement for a probe, or pin, in friction stir spot welding (FSSW) leads to an undesirable keyhole and ''hooking,'' which can influence the fracture path and weld strength. Furthermore, the full weld cycle for FSSW is typically longer than ideal for the automotive industry, being 2 to 5 seconds. Here, it is shown that using a novel pinless tool design it is possible to achieve high lap shear strength (~3.4 kN) in thin aluminum sheet (~1 mm thick), with short weld cycle times (<1 second). Several techniques have been exploited to study the material flow and mechanisms of weld formation in pinless FSSW, including high-resolution X-ray tomography, to understand the role of the tool design and weld parameters. Despite the ''simple'' nature of a pinless tool, material flow in the weld zone was found to be surprisingly complex and strongly influenced by surface features on the tool, which greatly increased the penetration of the plastic zone into the bottom sheet. Because of the rapid thermal cycle and high level of grain refinement, the weld zone was found to develop a higher strength than the parent material with little evidence of a heat affected zone (HAZ) after postweld natural aging.

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“…An ultrasonic welding process takes some milliseconds, with hardly changing properties of the welding samples. Ultrasonic welding is low cost and has a short welding cycle compared with electrical resistance spot welding [1] and friction stir welding [2]; ultrasonic welding also has the advantage of small distortion or shrinkage [3] compared to fusion welding [4]. With the development of high-power ultrasonic equipment, ultrasonic welding has been widely used in the industry of electron, electricity, packaging, aerospace, and nuclear energy due to its merits.…”

Section: Introductionmentioning

confidence: 99%

Microstructure and Mechanical Properties of Ultrasonic Welded Joint of 1060 Aluminum Alloy and T2 Pure Copper

Liu

Yan-shu

et al. 2017

Metals

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Abstract:The microstructure and mechanical properties of Al/Cu ultrasonic welding joints were investigated. Results show that: (i) the joint strength increased when the welding time increased within a certain range, and a maximal resistant force of 163.04 N was obtained when the welding duration and welding static pressure were 200 ms and 7.2 MPa, respectively; (ii) with a further increase of welding time, the bonding interface was gradually occupied by a thick strip layer of brittle Al 2 Cu (θ 2 ) phase, thus decreasing the strength; (iii) the maximum temperature in the welding region was 360 • C during the welding process, and a recrystallization phenomenon was identified near the welding interface; (iv) the average nanohardness of Cu, the Cu-Al interfacial reaction layer and Al were 1.04 GPa, 1.34 GPa, and 0.53 GPa, respectively, which is consistent with the formation of the intermetallic compound identified by energy-dispersive X-ray spectroscopy (EDS) and XRD analysis.

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Image analysis of electrode degradation in resistance spot welding of aluminium

Cited by 66 publications

References 5 publications

Some Tribological Influences on the Electrode-Worksheet Interface During Resistance Spot Welding of Aluminum Alloys

Some Tribological Influences on the Electrode-Worksheet Interface During Resistance Spot Welding of Aluminum Alloys

Material Interactions in a Novel Pinless Tool Approach to Friction Stir Spot Welding Thin Aluminum Sheet

Microstructure and Mechanical Properties of Ultrasonic Welded Joint of 1060 Aluminum Alloy and T2 Pure Copper

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