A review of advances in resistance spot welding of automotive sheet steels: emerging methods to improve joint mechanical performance

Soomro, Imtiaz Ali; Pedapati, Srinivasa Rao; Awang, Mokhtar

doi:10.1007/s00170-021-08002-5

Cited by 41 publications

(10 citation statements)

References 139 publications

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“…The electrode indentation or penetration plays an important role in reducing the nugget thickness. Ozen and Aslanar [19], Soomro et al [23] also reported that electrode penetration can reduce nugget thickness, which may have been observed at higher heat inputs. It was observed that the nugget height was higher on the DSS side than on the ASS side.…”

Section: Influence Of Heat Input On Geometrical Dimensions Of Nuggetmentioning

confidence: 96%

Examination on joining of 2 mm thick dissimilar stainless steel plates using resistance spot welding

Vignesh

2023

Eng. Res. Express

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In the present study, dissimilar metals such as austenitic stainless steel (ASS) and duplex stainless steel (DSS) with a thickness of 2 mm are joined by resistance spot welding process to investigate the welding metallurgy and failure behavior under different heat inputs. Non-uniform electrode impressions are observed on ASS and DSS sides due to their different thermal conductivity and electrical resistivity. The microstructure of the Fusion Zone (FZ) shows that higher heat input accelerates the growth of Intra Granular Austenite (IGA) due to faster cooling. Scanning electron microscopy (SEM) - Energy Dispersive X-ray (EDX) investigation at FZ showed that Chromium & Molybdenum decrease with increasing heat input due to a decrease in ferrite content. X-ray diffraction analysis confirmed that ferrite formation is limited at higher heat input. Microhardness study revealed that the higher hardness is in the middle of the weld nugget, which is due to the presence of equiaxed grains and IGA. The lowest hardness on the ASS side of Heat Affected Zone (HAZ) is due to the phenomenon of grain growth, and the HAZ DSS side has a higher hardness than DSS Base Metal (BM) due to the mechanism of solid solution strengthening. The tensile shear test showed that the tensile shear strength increases with the addition of heat. SEM Examination of the fracture surface revealed the presence of an equiaxed dimple structure on the ASS side, confirming ductile fracture, and torn bonds on the DSS side, confirming quasi-gap fracture due to the work-hardening ability of both plates. This study is carried out to understand the relationship between mechanical, metallurgical, and failure behaviours, because, researches on joining of dissimilar (AISI 316L and DSS 2205) stainless steel sheets using Resistance Spot Welding process is very limited and need to be studied in detail.

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Section: Influence Of Heat Input On Geometrical Dimensions Of Nuggetmentioning

confidence: 96%

Examination on joining of 2 mm thick dissimilar stainless steel plates using resistance spot welding

Vignesh

2023

Eng. Res. Express

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“…The quality of the joint is determined by the features of the weld nugget, which depends on the process parameters, 18,19 the surface conditions of the sheets in the contact zones, the thermal, mechanical and geometric properties (such as sheets thickness) of the base material and the type of electrode. 17 Concerning this, resistance spot weld joint failure represents one of the main reasons of vehicle crash test failure.…”

Section: Resistance Spot Weldingmentioning

confidence: 99%

“…20 For each material mix, there is a current range in which a good weld nugget is produced; excessive heat input can lead to the ejection of the liquid metal from the nugget, while low heat input may result in insufficient melting. 18,19,21 Although, the process is well established for joining steel sheets, the same cannot be said for joining aluminum alloy sheets, which has rapidly become the material of choice in the design of lightweight and environmentally friendly vehicles. The reason lies in the physical-chemical properties of aluminum.…”

Section: Resistance Spot Weldingmentioning

confidence: 99%

Innovative joining technologies for lightweight material vehicles

Papa,

Panico,

Carandente

et al. 2024

Proceedings of the Institution of Mechanical Engineers, Part C:

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The transport industry is one of the most important for society and its economic growth. In Europe, this is especially true for road transport, which is an essential pillar for employment, trade, and economic development. The challenge is to minimize energy and cost and maximize efficiency while ensuring comfort and safety. This is the driving force behind technological progress that with social changes (such as, changing consumer preferences, greater environmental awareness) and political changes is revolutionizing the way people and goods move. Nevertheless, the selection of lightweight materials is negligible; it could involve new manufacturing technologies and joining techniques. Jaguar Land Rover (JLR) has been one of the prominent car producers employing aluminum alloys since 2003. A typical JLR monocoque is characterized by 90% aluminum stampings components made of 5xxx and 6xxx series aluminum alloys. Audi Space Frame (ASF) represents an alternative interpretation of improved lightweight frame architecture, and it is characterized by aluminum for more than 80% with the residual parts in CFRP used for rear panels, tunnel and the components useful to higher torsional stiffness. A 30% weight decrease is reached with respect to traditional steel corresponding elements. This review shows an overview of the challenges and opportunities for automotive body structures in the coming years while maintaining the goal of reducing mass and improving sustainability without increasing costs and impacting safety. This manuscript first evaluates how we can reduce mass in vehicles minimizing the carbon footprint and developing recyclable structures. The potential of new materials will be shown in light of the design constraints and the choice of technology used. The final remarks will discuss opportunities for engineering innovation dictated by this period of great changes and needs.

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“…Resistance spot welding (RSW) is widely employed for joining metal sheets in the manufacturing of automobiles, trucks trailers, buses, recreational vehicles, office furniture and appliances, railway vehicles, aeroplane structures and also for aeronautical and space applications [1]. In the automotive industry, RSW, because of its low cost, high speed and high degree of adaptability for automation in mass production, is the predominant process in sheet metal joining [2][3][4][5][6][7][8][9].…”

Section: Introductionmentioning

confidence: 99%

Effect of post-welding sensitisation on the degree of sensitisation of the welding zones of AISI 304 resistance spot welding joints studied by using an electrochemical minicell

Tiedra

Martín

2023

Corrosion Engineering, Science and Technology

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In resistance spot welding (RSW) joints of austenitic stainless steel (ASS), a small-scale electrochemical cell (minicell) was used for assessing individually, on each of the three welding zones, of size less than 1000 µm (fusion zone (FZ), heat affected zone (HAZ) and base metal (BM)), the combined effect of a RSW process and post-welding sensitisation on the degree of sensitisation (DOS). The results show that the three welding zones have different microstructures that make each of them respond differently to post-welding sensitisation. The DOS varies with post-welding sensitisation time in all three welding zones, but it varies at a different rate in each welding zone (the highest rate in the FZ). This variation is due to the fact that when the DOS reaches a certain level, which is observed when plotting the reactivation charge (Q r ) versus the post-welding sensitisation time, a microstructural regeneration occurs.

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A review of advances in resistance spot welding of automotive sheet steels: emerging methods to improve joint mechanical performance

Cited by 41 publications

References 139 publications

Examination on joining of 2 mm thick dissimilar stainless steel plates using resistance spot welding

Examination on joining of 2 mm thick dissimilar stainless steel plates using resistance spot welding

Innovative joining technologies for lightweight material vehicles

Effect of post-welding sensitisation on the degree of sensitisation of the welding zones of AISI 304 resistance spot welding joints studied by using an electrochemical minicell

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