Use of electrode displacement signals for electrode degradation assessment in resistance spot welding

Panza, Luigi; Maddis, Manuela De; Spena, Pasquale Russo

doi:10.1016/j.jmapro.2022.01.060

Cited by 21 publications

(5 citation statements)

References 23 publications

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“…It should be noted that the electrode tip diameter is not recorded after a fixed number of welds. This is because it was found that the electrode tip diameter increased more at the beginning and then tended to increase slowly [14]. In this case, the electrode tip diameter was measured During continuous welding, the carbon paper was utilised to record the changes in diameter of the electrode tip after several welding points.…”

Section: Experimental Procedures Experimental Materials and Welding C...mentioning

confidence: 99%

“…These data can be used to build a model based on machine learning algorithms to predict the wear of the electrode and the number of welds. Panza et al [14] built an artificial neural network model using the feature values extracted from the electrode displacement signal as the input to the model, and the predicted value of the model was the contact area between the electrodes and the steel sheets. The model successfully predicted electrode wear and degradation.…”

Section: Introductionmentioning

confidence: 99%

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Assessing Electrode Characteristics in Continuous Resistance Spot Welding of BH 340 Steel Based on Dynamic Resistance

Zhao,

Vdonin,

Slobodyan

et al. 2023

JMMP

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The aim of this investigation is to offer a data-based scheme for predicting electrode wear in resistance spot welding. One of the major factors affecting the mechanical properties of spot welds and the variation in weld quality is electrode wear and alloying. In this study, Rogowski coils and twisted pairs attached to the top and bottom electrodes were used to obtain the welding current and the voltage between the electrodes in the welding process, thereby calculating the dynamic resistance value during the welding process. The electrode tip diameter was obtained from the pressure exerted by the upper and lower electrodes on the carbon paper when the current was cut off and was regarded as an indicator of electrode wear. By continuously welding 0.5 mm thick BH 340 steel plates until the electrode failed, the dynamic resistance signal was recorded in real time. Simultaneously, the electrode diameter after every several welds was also recorded. On this basis, the correlation between electrode tip diameter and dynamic resistance is studied. In order to quantitatively study the mapping relationship between dynamic resistance and electrode wear, 10 characteristic values were extracted from the dynamic resistance, and the stepwise regression method was used to obtain the regression formula between the characteristic values and the electrode tip diameter. Using new data to verify the effectiveness of the regression model, the acquired results display that the maximum error between the predicted value of the electrode tip diameter and the measured value obtained by the regression equation with the interactive quadratic term is 0.3 mm, and the corresponding relative error is 7.69%. When welding with a new pair of electrodes, the maximum absolute error was 0.72 mm, and the relative error of the model prediction is within 20% according to the linear regression model with interaction terms. This indicates that this regression model is barely satisfactory for monitoring electrode condition.

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Section: Experimental Procedures Experimental Materials and Welding C...mentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Assessing Electrode Characteristics in Continuous Resistance Spot Welding of BH 340 Steel Based on Dynamic Resistance

Zhao,

Vdonin,

Slobodyan

et al. 2023

JMMP

View full text Add to dashboard Cite

show abstract

“…would affect these phenomena. 58,[61][62][63] A shear stress is applied in the sheets' interface during the tensile-shear test. The maximum shear stress applied τ WN can be calculated using equation ( 2) 57 :…”

Section: Mechanical Propertiesmentioning

confidence: 99%

Microstructure and tensile-shear behavior of dissimilar resistance spot welds between 2304 duplex stainless steel and Inconel 718 superalloy

Badkoobeh

Mostaan

Rafiei

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part L:

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Dissimilar joints between duplex stainless steels and nickel-based superalloys are of high significance in some industries. In this research, 2304 duplex stainless steel and Inconel 718 superalloy were welded by the resistance spot welding technique. The studies showed that the fusion zone microstructure was composed of a dendritic structure related to the grains of nickel-based solid solution ( γ-phase) and γ′ islands. The heat-affected zone microstructure of 2304 duplex stainless steel includes the austenite phase with a slight volume fraction and the ferrite phase with a high volume fraction. The austenite phase was formed with two morphologies of Widmanstätten and grain boundary allotriomorphs. The heat-affected zone microstructure of Inconel 718 superalloy also contained γ phase (nickel-based solid solution), annealing twins, and some precipitates. The results of the tensile-shear test revealed that tensile-shear strength (i.e. peak load) and fracture energy were increased by increasing the welding current from 1 to 2 kA and the welding time from 1 to 2 s. However, they were reduced by increasing the welding current from 2 to 4 kA and the welding time from 2 to 4 s. This was caused by the surface splash between the electrodes and the sheets. In the above-mentioned range, an increase in the welding current and time may also intensify the surface splash. It was also found that when the welding time was constant (i.e. 2 s), the spot weld obtained at the welding current of 1 kA failed by interfacial fracture mode. All spot welds obtained at the welding currents of 2, 3, and 4 kA failed by pull-out fracture mode. On the other hand, all spot welds associated with the welding times of 1, 2, 3, and 4 s failed by PF mode when the welding current was constant (i.e. 3 kA).

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“…Similarly, many studies focus on the influence of mechanical problems and weld quality. In relation to the wear of the machine, the different studies have focused on the detection of the wear of the electrodes as these are a fundamental piece in the application of pressure and current to the welding point [ 20 , 21 ]. Nevertheless, at this time, there is no research that focuses its study on the detection of wear not only of the electrodes but of all the elements involved in the secondary circuit of the resistance welding gun.…”

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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Use of electrode displacement signals for electrode degradation assessment in resistance spot welding

Cited by 21 publications

References 23 publications

Assessing Electrode Characteristics in Continuous Resistance Spot Welding of BH 340 Steel Based on Dynamic Resistance

Assessing Electrode Characteristics in Continuous Resistance Spot Welding of BH 340 Steel Based on Dynamic Resistance

Microstructure and tensile-shear behavior of dissimilar resistance spot welds between 2304 duplex stainless steel and Inconel 718 superalloy

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

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