The effects of the welding current on heat input, nugget geometry, and the mechanical and fractural properties of resistance spot welding on Mg/Al dissimilar materials

Hayat, Fatih

doi:10.1016/j.matdes.2010.11.015

Cited by 95 publications

(37 citation statements)

References 18 publications

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“…Unfortunately, direct joints between aluminum and magnesium suffer from poor strength and ductility. Such poor mechanical properties are a result of development of brittle inter-metallic phase, i.e, Mg 17 Al 12 and Al 3 Mg 2 during welding, as already investigated in literature [5][6][7][8] . Thus, in order to achieve a strong joint during welding, direct contact between aluminum and magnesium should be avoided.…”

Section: Introductionmentioning

confidence: 77%

Resistance spot welding between aluminum and magnesium with zinc and tin insert

Wang¹,

Qiu²,

Li³

et al. 2017

Proceedings of the 2017 6th International Conference on Measurement, Instrumentation and Automation (ICMIA 2017)

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Abstract. In this paper, the dissimilar resistance spot welding of A6061 aluminum alloy and AZ31 magnesium alloy sheet is studied, and the middle layer is Zn and Sn. The results show that the addition of Zn and Sn as the intermediate layer can effectively prevent the formation of intermetallic compounds, and can enhance the quality of the joint. It is found that with the increase of welding current, the tensile shear load of the welded joint increases first and then begins to decrease. Mg-Al compound formation was not observed at the interface of the joint. The results show that the addition of the middle layer hinders the direct contact between aluminum and magnesium, inhibits the interface reaction and improves the performance of the joint.

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Section: Introductionmentioning

confidence: 77%

Resistance spot welding between aluminum and magnesium with zinc and tin insert

Wang¹,

Qiu²,

Li³

et al. 2017

Proceedings of the 2017 6th International Conference on Measurement, Instrumentation and Automation (ICMIA 2017)

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“…The EDS analysis results, presented in Table (spectra 1 and 2) revealed that the Al–Mg IMCs are present on the fracture surface. The low strength, premature nugget failure, and the brittle morphology of the fracture surface can be attributed to the formation of hard and brittle Al–Mg IMCs, such as Al 3 Mg 2 and Al 12 Mg 17 , inside the nugget …”

Section: Resultsmentioning

confidence: 99%

“…Several welding methods were investigated for joining Al to Mg alloys, such as laser welding, vacuum diffusion bonding, gas tungsten arc welding, resistance spot welding, ultrasonic spot welding and friction stir welding . Previous studies demonstrated that the Al–Mg IMCs such as Al 3 Mg 2 and Al 12 Mg 17 have a harmful effect on the strength of Mg/Al joint and could hardly be prevented during the welding process . To reduce the formation of Al–Mg IMCs, an interlayer made of a third metal, such as copper, steel, cerium, titanium and nickel, was placed between Al and Mg coupons during welding.…”

Section: Introductionmentioning

confidence: 99%

Fatigue behaviour of dissimilar Al 5052 and Mg AZ31 resistance spot welds with Sn‐coated steel interlayer

Sun

Behravesh

et al. 2016

Fatigue Fract Eng Mat Struct

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The fatigue property of dissimilar spot welds between an aluminium alloy (AA5052) and a magnesium alloy (AZ31) was studied in this research. The AA5052 and AZ31 coupons were resistance spot welded together by using an interlayer of Sn‐coated steel between the two coupons. The fatigue test results revealed that the Mg/Al joints had the same level of fatigue strength as Mg/Mg resistance spot welds. It was found that within the life range of Nf < 105 cycles, Mg/Al welds degraded faster than Mg/Mg joints. This was attributed to the larger bending moment on the plane of fatigue failure in the Mg/Al welds. Three failure modes were observed under different cyclic loading regimes: Al/steel interfacial failure, Mg coupon failure and Al coupon failure. Fatigue fracture surface of Mg/Al welds consisted of two distinct regions: crack propagation region with brittle morphology and final rupture with ductile morphology.

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“…This will affect the nugget size and strength of the weld joint [15]. The nugget size and weld joint strength depend on the resistance and welding time, so the welding duration influences the mechanical properties of the weld joints [16,17]. Melting occurs as a result of the relationship between welding current, welding time, and electrode force, as shown in schematic diagram RSW cycle Figure 2, where is welding current, is welding time, and is electrode force.…”

Section: Rsw Processmentioning

confidence: 99%

Resistance Spot Welding Optimization Based on Artificial Neural Network

Arunchai

Sonthipermpoon

Apichayakul

et al. 2014

International Journal of Manufacturing Engineering

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Resistance Spot Welding (RSW) is processed by using aluminum alloy used in the automotive industry. The difficulty of RSW parameter setting leads to inconsistent quality between welds. The important RSW parameters are the welding current, electrode force, and welding time. An additional RSW parameter, that is, the electrical resistance of the aluminum alloy, which varies depending on the thickness of the material, is considered to be a necessary parameter. The parameters applied to the RSW process, with aluminum alloy, are sensitive to exact measurement. Parameter prediction by the use of an artificial neural network (ANN) as a tool in finding the parameter optimization was investigated. The ANN was designed and tested for predictive weld quality by using the input and output data in parameters and tensile shear strength of the aluminum alloy, respectively. The results of the tensile shear strength testing and the estimated parameter optimization are applied to the RSW process. The achieved results of the tensile shear strength output were mean squared error (MSE) and accuracy equal to 0.054 and 95%, respectively. This indicates that that the application of the ANN in welding machine control is highly successful in setting the welding parameters.

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The effects of the welding current on heat input, nugget geometry, and the mechanical and fractural properties of resistance spot welding on Mg/Al dissimilar materials

Cited by 95 publications

References 18 publications

Resistance spot welding between aluminum and magnesium with zinc and tin insert

Resistance spot welding between aluminum and magnesium with zinc and tin insert

Fatigue behaviour of dissimilar Al 5052 and Mg AZ31 resistance spot welds with Sn‐coated steel interlayer

Resistance Spot Welding Optimization Based on Artificial Neural Network

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