The Influence of Welding Parameters on the Nugget Formation of Resistance Spot Welding of Inconel 625 Sheets

Abstract

A 2D axisymmetric electro-thermo-mechanical finite element (FE) model is developed to investigate the effect of current intensity, welding time, and electrode tip diameter on temperature distributions and nugget size in resistance spot welding (RSW) process of Inconel 625 superalloy sheets using ABAQUS commercial software package. The coupled electro-thermal analysis and uncoupled thermal-mechanical analysis are used for modeling process. In order to improve accuracy of simulation, material properties including physical, thermal, and mechanical properties have been considered to be temperature dependent. The thickness and diameter of computed weld nuggets are compared with experimental results and good agreement is observed. So, FE model developed in this paper provides prediction of quality and shape of the weld nuggets and temperature distributions with variation of each process parameter, suitably. Utilizing this FE model assists in adjusting RSW parameters, so that expensive experimental process can be avoided. The results show that increasing welding time and current intensity lead to an increase in the nugget size and electrode indentation, whereas increasing electrode tip diameter decreases nugget size and electrode indentation.

Investigation Effect of ECR’s Thickness and Initial Value of Resistance Spot Welding Simulation using 2-Dimensional Thermo-Electric Coupled

“…According to Ashtiani and Zarandooz 8) , the RSW process has some three types of physics phenomenon coupled interaction, which is difficult to analyze: thermal, electric, and metallurgical phenomena. Thus, making RSW simulation more complex and harder to get near an actual or experimental result.…”

Fatigue life analysis in the residual stress field due to resistance spot welding process considering different sheet thicknesses and dissimilar electrode geometries

“…In recent years, the effects of process parameters have been studied on the temperature distribution and nugget diameter of Inconel 625 sheet joints by FE analysis. 16 The results showed that increasing the electric current and welding time led to an increase in nugget diameter and electrode penetration depth. In addition, the weld nugget size and electrode penetration depth are reduced by increasing the diameter of the electrode cross-section.…”

Validated Multi-Physical Finite Element Modelling of the Spot Welding Process of the Advanced High Strength Steel DP1200HD

“…So far, the only viable approach that allows monitoring of these transient fields is a numerical process simulation by means of the finite element (FE) method. The literature reports on a number of FE models of RSW processes [12][13][14][15][16]. In most of those publications only the electrical-thermal-mechanical coupling is considered, whereas the metallurgical and mechanical effects of phase transformations are not covered [17] or only dealt with by applying some simplifications [18,19].…”