Weld nugget formation in resistance spot welding of new lightweight sandwich material

Tanco, J. Sagüés; Nielsen, Chris Valentin; Chergui, Azeddine; Zhang, Wenqi; Bay, Niels

doi:10.1007/s00170-015-7108-0

Cited by 26 publications

(13 citation statements)

References 5 publications

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“…Numerical simulations were performed in SORPAS ® 3D and the compatibility of the diameter of the spot welds were compared to the experimental results. Results presented in both articles [12,13] indicate the high industrial potential of the proposed method of joining. However, obtaining the required quality of joints, the welding condition, and parameters must be precisely controlled.…”

Section: Introductionmentioning

confidence: 95%

“…The authors describe both the optimal technological parameters (electrode force, welding current, welding time, number of pulses, distance between the electrode and the shunt tool) as well as the results of tests carried out on the joints (fracture load in tensile shearing test, hardness in the fusion zone and HAZ, macro/micrograph and SEM/EDS examinations). Shunt current-assisted resistance spot welding was also analyzed by Tanco et al [13], where the authors developed a technology for resistance spot welding three sheets of DC06 1.5 mm + Litecor 0.8 mm + DC06 1.5 mm by selecting process parameters that allowed for good quality joints to be obtained. Numerical simulations were performed in SORPAS ® 3D and the compatibility of the diameter of the spot welds were compared to the experimental results.…”

Section: Introductionmentioning

confidence: 99%

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Development of Resistance Spot Welding Processes of Metal–Plastic Composites

et al. 2021

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Metal–plastic composites (MPCs) are gaining importance mainly due to high strength to weight ratio. They consist of three layers, two outer metallic cover sheets, and a plastic core. The presence of that inner plastic layer makes them rather unsuitable for joining by means of any conventional welding processes, which significantly reduces the application range of MPC. In this work, three various resistance spot welding (RSW)-based concepts were developed to overcome that limitation and join Litecor to DP600 steel. In all cases, a dedicated initial stage was implemented to RSW, which was aimed at removing the non-conductive polymer layer from the welding zone and creating the proper electrical contact for the resistance welding. These were, namely: (i) shunt current-assisted RSW; (ii) induction heating-assisted RSW; and (iii) ultrasonic-assisted RSW. The development of each concept was supported by finite element modeling, which was focused on setting the proper process parameters for polymer layer removal. Finally, the macro- and microstructure of exemplary RSW joints are shown and the most common spot weld features as well as the further development possibilities are discussed.

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Section: Introductionmentioning

confidence: 95%

Section: Introductionmentioning

confidence: 99%

Development of Resistance Spot Welding Processes of Metal–Plastic Composites

et al. 2021

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“…An early version of a micro-sandwich was developed by Bhart et al [ 13 ], where the cell walls of a honeycomb pattern consisted of a micro-sandwich structure. Micro-sandwich materials typically consist of metal skins with a polymeric core, see, e.g., in [ 14 , 15 , 16 ]. Several micro-sandwiches have been presented in the literature, e.g., Hylite [ 17 ].…”

Section: Introductionmentioning

confidence: 99%

Novel Methodology for Experimental Characterization of Micro-Sandwich Materials

et al. 2021

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Lightweight components are in demand from the automotive industry, due to legislation regulating greenhouse gas emissions, e.g., CO2. Traditionally, lightweighting has been done by replacing mild steels with ultra-high strength steel. The development of micro-sandwich materials has received increasing attention due to their formability and potential for replacing steel sheets in automotive bodies. A fundamental requirement for micro-sandwich materials to gain significant market share within the automotive industry is the possibility to simulate manufacturing of components, e.g., cold forming. Thus, reliable methods for characterizing the mechanical properties of the micro-sandwich materials, and in particular their cores, are necessary. In the present work, a novel method for obtaining the out-of-plane properties of micro-sandwich cores is presented. In particular, the out-of-plane properties, i.e., transverse tension/compression and out-of-plane shear are characterized. Test tools are designed and developed for subjecting micro-sandwich specimens to the desired loading conditions and digital image correlation is used to qualitatively analyze displacement fields and fracture of the core. A variation of the response from the material tests is observed, analyzed using statistical methods, i.e., the Weibull distribution. It is found that the suggested method produces reliable and repeatable results, providing a better understanding of micro-sandwich materials. The results produced in the present work may be used as input data for constitutive models, but also for validation of numerical models.

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“…Tanco et al. 4 utilized resistance spot welding (RSW) with a shunt tool to connect steel–polymer laminates with monolithic steel sheets. The first pulse, with the use of a shunt tool, is used to squeeze out the nonconductive polymer core and obtain a localized steel–steel contact.…”

Section: Introductionmentioning

confidence: 99%

Invisible mechanical lap joints for metal–polymer laminates

Batista

Pragana

Bragança

et al. 2020

Proceedings of the Institution of Mechanical Engineers, Part L:

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Joining by compression of metallic inserts has been recently developed by the authors to create invisible lap joints between metal and polymer laminates. This paper revisits the process with the objective of proposing a new type of bi-material (polymer–metal) cylindrical insert for lightweight construction applications that is capable of ensuring complete filling of the joint at the end of stroke without increasing the forming force and the risk of sheet bending. The presentation is built upon a combined experimental and finite element research work focused on the modes of deformation, formability limits, forming forces, and resistance strength that lap joints produced with the new bi-material cylindrical inserts are able to withstand before failing. Results allowed designing a simple and easy to fabricate bi-material cylindrical insert that overcomes the main problems that have been pointed out to the metallic inserts earlier proposed by the authors.

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Weld nugget formation in resistance spot welding of new lightweight sandwich material

Cited by 26 publications

References 5 publications

Development of Resistance Spot Welding Processes of Metal–Plastic Composites

Development of Resistance Spot Welding Processes of Metal–Plastic Composites

Novel Methodology for Experimental Characterization of Micro-Sandwich Materials

Invisible mechanical lap joints for metal–polymer laminates

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