Resistance spot welding with variable electrode force—development and benefit of a force profile to extend the weldability of 22MnB5+AS150

Wohner, Maximilian; Mitzschke, Niels; Jüttner, Sven

doi:10.1007/s40194-020-01001-2

Cited by 17 publications

(5 citation statements)

References 22 publications

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“…For example at welding current equal to 12 kA, increasing with 0.4 mm in increasing of welding time from 10 to 13 cycles. In addition, according to Figure 8a and 8b, there is a little decrease in the nugget diameter with the increase in the force of the electrode [31,32].…”

Section: Effect Of Welding Current On Geometrical Parameters Of Rswmentioning

confidence: 84%

Effect of welding parameters on critical stress intensity factor for coach peel and tensile shear joints of 316L stainless steel

Benchadli,

Benachour,

Sebaa

et al. 2024

Preprint

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The aim of this study was to evaluate the fracture toughness of resistance spot welded (RSW) lap joints and coach peel joints of 316L stainless steels. In the current work, fracture toughness of RSW lap joints and coach peel joints were calculated respectively from the results of shearing tensile tests and peel tensile tests. The effects of welding parameters (welding current, welding time, electrode force) of RSW on fracture toughness were investigated using fracture mechanics concept based on ZHANG approaches. The fracture toughness decreases relatively with welding current from 8 kA to 16. Also, the effects of welding parameters on nugget are studied where the increase in welding current increases the nugget diameter.

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Section: Effect Of Welding Current On Geometrical Parameters Of Rswmentioning

confidence: 84%

Effect of welding parameters on critical stress intensity factor for coach peel and tensile shear joints of 316L stainless steel

Benchadli,

Benachour,

Sebaa

et al. 2024

Preprint

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“…Therefore, the expulsion event is one of the most essential factors to detect and characterize the weld nugget quality assurance [ 19 ]. The possible outcome of the expulsion formation can also be generated, when the electrode displacement exceeds the limit of the maximum expansion, leading to an explicit spatter formation [ 11 ]. Consideration can be taken, as the expulsion tends to increase when a too low or too high welding force is applied [ 10 ].…”

Section: Resultsmentioning

confidence: 99%

“…To define the best quality of Ti-6Al-4V weld nugget strength, it is important to investigate the weld nugget’s physical and mechanical properties. The RSW parameters such as the welding current, time, and force are proved to be the most significant affected parameters to develop the weld nugget properties [ 4 , 5 , 6 , 7 , 8 , 9 , 10 , 11 , 12 , 13 , 14 , 15 , 16 , 17 , 18 , 19 , 20 , 21 , 22 ]. Similar materials with different thicknesses were previously studied [ 23 , 24 ].…”

Section: Introductionmentioning

confidence: 99%

An Exploratory Study on Resistance Spot Welding of Titanium Alloy Ti-6Al-4V

et al. 2021

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Resistance spot welding (RSW) is one of the most effective welding methods for titanium alloys, in particular Ti-6Al-4V. Ti-6Al-4V is one of the most used materials with its good ductility, high strength, weldability, corrosion resistance, and heat resistance. RSW and Ti-6Al-4V materials are often widely used in industrial manufacturing, particularly in automotive and aerospace industries. To understand the phenomenon of resistance spot weld quality, the physical and mechanical properties of Ti-6Al-4V spot weld are essential to be analyzed. In this study, an experiment was conducted using the Taguchi L9 method to find out the optimum level of the weld joint strength. The given optimum level sample was analyzed to study the most significant affecting RSW parameter, the failure mode, the weld nugget microstructure, and hardness values. The high heat input significantly affect the weld nugget temperature to reach and beyond the β-transus temperature. It led to an increase in the weld nugget diameter and the indentation depth. The expulsion appeared in the high heat input and decreased the weld nugget strength. It was caused by the molten material ejection in the fusion zone. The combination of high heat input and rapid air cooling at room temperature generated a martensite microstructure in the fusion zone. It increased the hardness, strength, and brittleness but decreased the ductility.

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“…In previous investigations, a method for detecting problems in the secondary circuit of the welding guns was investigated by analysing the existing data in the welding timer (see [ 5 ]).…”

Section: Background and Objectivesmentioning

confidence: 99%

“…Therefore, due to the complexity of the process, there are many parameters that influence the final quality of the welding joint. The different parameters and influences on the final quality have been studied by different authors, highlighting the importance of pressure, current, electrode wear, welding shunt effect, or electrode misalignment [ 5 , 6 , 7 , 8 ]. Therefore, it is essential for the industry to guarantee the stability of the process to avoid the variations in the parameters that have an impact on welding.…”

Section: Introductionmentioning

confidence: 99%

Incipient Wear Detection of Welding Gun Secondary Circuit by Virtual Resistance Sensor Using Mahalanobis Distance

Ibañez

García²,

Soret

et al. 2023

Sensors

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Wear of the secondary of the welding gun, caused by mechanical fatigue or due to a bad parameterization of the welding points, causes an increase in quality problems such as non-existent welds or a reduced weld nugget size. In addition to quality problems, this defect causes production stoppages that affect the final cost of the manufactured part. Different studies have focused on evaluating the importance of different welding parameters, such as current, in the final quality of the welding nugget. However, few studies have focused on preventing weld command parameters from degrading or changing. This investigation seeks to determine the wear of the secondary circuit to avoid variability in the current supplied to the welding point caused by this defect and the increase in circuit resistance, especially in industrial environments. In this work, a virtual sensor is developed to estimate the resistance of the welding arm based on previous research, which has shown the possibility of detecting secondary wear by analysing the duty cycle of the power circuit. From the data of the virtual sensor, an anomaly detection method based on the Mahalanobis distance is developed. Finally, an integral system for detecting secondary wear of welding guns in real production lines is presented. This system establishes performance thresholds based on the analysis of the Mahalanobis distance distribution, allowing monitoring of the secondary circuit wear condition after each welding cycle. The results obtained show how the system can detect incipient wear in welding guns, regardless of which part of the secondary the wear occurs, improving decision-making and reducing quality problems.

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Resistance spot welding with variable electrode force—development and benefit of a force profile to extend the weldability of 22MnB5+AS150

Cited by 17 publications

References 22 publications

Effect of welding parameters on critical stress intensity factor for coach peel and tensile shear joints of 316L stainless steel

Effect of welding parameters on critical stress intensity factor for coach peel and tensile shear joints of 316L stainless steel

An Exploratory Study on Resistance Spot Welding of Titanium Alloy Ti-6Al-4V

Incipient Wear Detection of Welding Gun Secondary Circuit by Virtual Resistance Sensor Using Mahalanobis Distance

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