Welding parameters obviously determine the joint quality during the resistance spot welding process. This study aimed to investigate the effect of welding current and electrode force on the heat input and the physical and mechanical properties of a SS316L and Ti6Al4V joint with an aluminum interlayer. The weld current values used in this study were 11, 12, and 13 kA, while the electrode force values were 3, 4, and 5 kN. Welding time and holding time remained constant at 30 cycles. The study revealed that, as the welding current and electrode force increased, the generated heat input increased significantly. The highest tensile-shear load was recorded at 8.71 kN using 11 kA of weld current and 3 kN of electrode force. The physical properties examined the formation of a brittle fracture and several weld defects on the high current welded joint. The increase in weld current also increased the weld diameter. The microstructure analysis revealed no phase transformation on the SS316L interface; instead, the significant grain growth occurred. The phase transformation has occurred on the Ti6Al4V interface. The intermetallic compound layer was also investigated in detail using the EDX (Energy Dispersive X-Ray) and XRD (X-Ray Diffraction) analyses. It was also found that both stainless steel and titanium alloy have their own fusion zone, which is indicated by the highest microhardness value.
Titanium alloy Ti-6Al-4V properties advantage gives it a well-known reputation for decades as a reliably material used in a wide range and specific application of resistance spot welded joint such as automotive & aviation products. High strength joint is created depends on the welding parameters used in resistance spot welding. Particular problems occurred about the effect of welding parameters on pure titanium and titanium alloy mechanical and physical properties from previous researches. Some pores and acicular α’ phase appeared in the microstructure, which caused partial interfacial failure mode in the tensile testing. This study is conducted to study the influence of welding parameters for Ti-6Al-4V weld nugget mechanical and physical properties and discover its optimum level of parameters. Tensile-shear testing is used to observed the optimum level. In the optimum level microstructure result reveals that in the weld nugget zone as a fusion zone the lamellar α+β is dominantly observed, this contrasts sharply with the base metal and the heat-affected zone where the primary α and β phase appear to be more dominant. The highest hardness value is discovered in the weld nugget area near the center proving the contribution of the lamellar α+β on this area.
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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