Resistance ceramic-filled annular welding of DP980 high-strength steel

Ren, Daxin; Zhao, Dewang; Zhao, Kunmin; Liu, Liming; He, Zhubin

doi:10.1016/j.matdes.2019.108118

Cited by 11 publications

(2 citation statements)

References 18 publications

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“…Therefore, the quality and performance of spot welding must be considered to ensure the best safe design of the car [2,3]. High-strength steels have many significant characteristics, such as a high strength-weight ratio and fatigue resistance, so they are used in the automotive industry instead of mild steel to decrease the car's body weight and to improve fuel efficiency [4]. During resistance spot welding, the heat is produced because of the flow of high electrical current through the welding parts according to Joule law:…”

Section: Introductionmentioning

confidence: 99%

Optimization Process of Double Spots Welding of High Strength Steel Using in the Automotive Industry

Khaleel¹,

Mahmood²,

Khoshnaw³

2022

ETJ

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 Double spot welding for high-strength low alloy steel which is a new steel grade.  The results showed that optimum welding parameters are welding current of 8800 Amp, welding time of 20 cycles, and electrode force of 1900 N.  Pull out failure mode because of high plastic deformation.  The shunt effect phenomenon influences the mechanical properties of double spot welding.Resistance Spot Welding (RSW) is one of the most important welding techniques used in the automotive industry because it is an economic process and is suitable for many materials. Many parameters affect the mechanical and microstructural properties of nugget formation and its strength, like welding current, electrode force, and welding time. Therefore, optimizing the RSW process to get the optimum welding parameters is necessary for automobile manufacturing companies. High-strength steel is widely used in the automotive industry because of its superior characteristics such as high strength-weight ratio, ductility, fatigue, and corrosion resistance. This paper presents an optimization process for RSW using the Taguchi method for high strength low alloy steel (HSLA) DOCOL 500 LA, considered a new steel grade. Two spots were used in this work.The mechanical and microstructural tests are achieved to get the maximum nugget strength, nugget diameter, different welding zones microstructures, microhardness values, and failure modes. The results showed that optimum welding parameters were welding current of 8800 Amp, welding time of 20 cycles, and electrode force of 1900 N. The failure mode for optimum conditions was a full pullout with tearing of the welded sheets because of high plastic deformation and absorbed energy. The maximum microhardness value is in the fusion zone, the heat-affected region, and finally, in the base material due to the nugget zone's rapid melting and solidification process.

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Section: Introductionmentioning

confidence: 99%

Optimization Process of Double Spots Welding of High Strength Steel Using in the Automotive Industry

Khaleel¹,

Mahmood²,

Khoshnaw³

2022

ETJ

View full text Add to dashboard Cite

show abstract

“…By optimizing the contact state and current state, the distribution of welding energy in time and space has outstanding "flexible" and "quantitative controllable" characteristics. Furthermore, changing the forming method of solder joints, realizing the synergistic control of large-size solder joints and high-quality forming, and obtaining excellent microstructure [14,15]. Fig.…”

Section: Introductionmentioning

confidence: 99%

Experimental and Numerical Simulation Study on Forming and Thermal Distribution of a New Composite Annular Electrode Joint

Zhao

Zhang²,

Ren³

et al. 2022

Preprint

Self Cite

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When welding high-strength steel and ultra-thin plates, traditional resistance spot welding has technical problems such as a narrow process window and difficulty in ensuring both welding strength and forming quality, making it one of the bottlenecks in the manufacture of high-end structural parts in the fields of vehicles, aviation and aerospace. The core reason is that the traditional spot welding thermal cycle mode is single, the energy is highly concentrated, and the controllability is poor. Therefore, there is an inconsistency between its energy distribution and nugget quality. In view of the above difficulties, a new idea of resistance spot welding of special-shaped electrodes based on energy distribution design is proposed. By inlaying insulating ceramics and other materials on the electrode end face, a "composite annular electrode" is prepared to realize the regulation of energy distribution in the welding process. In this paper, the thermo-electric-structural coupling FEM of a new composite electrode is established to reveal the detailed influence of the diameter of the ceramic core on the joint forming and thermal distribution. And the optimal ceramic core diameter is optimized for ultra-thin plates and high-strength steel plates commonly used in automobiles.

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Experimental and numerical simulation on forming and thermal distribution of a new composite annular electrode joint

Zhao

Zhang

Ren

et al. 2022

Int J Adv Manuf Technol

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Resistance ceramic-filled annular welding of DP980 high-strength steel

Cited by 11 publications

References 18 publications

Optimization Process of Double Spots Welding of High Strength Steel Using in the Automotive Industry

Optimization Process of Double Spots Welding of High Strength Steel Using in the Automotive Industry

Experimental and Numerical Simulation Study on Forming and Thermal Distribution of a New Composite Annular Electrode Joint

Experimental and numerical simulation on forming and thermal distribution of a new composite annular electrode joint

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