A review of electrical contact resistance modeling in resistance spot welding

Hamedi, Mohsen; Atashparva, M.

doi:10.1007/s40194-016-0419-4

Cited by 55 publications

(21 citation statements)

References 38 publications

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“…The total electrical resistance of two rails includes three components, namely the rail resistance ( R b ), the contact resistance between the electrodes and the rails ( R c ), and the contact resistance between the two rails ( R f ). Furthermore, the electrical resistance of two rails is given as follows 16 …”

Section: Governing Equationsmentioning

confidence: 99%

“…Due to the variation of electrical resistance versus the temperature and upsetting force, 16–18 R is not considered constant. Electrical resistance is modeled in heat source by using equation (2) and Q = VI (i.e.…”

Section: Governing Equationsmentioning

confidence: 99%

“…The heat source is modeled using equation Q = RI 2 in heating and flashing stage to include the resistance effect as presented by equation (6), and in upsetting stage Q = VI (V and I are electrical voltage and current of the FBW machine) is assumed. Electrical resistance (R) versus the temperature and upsetting force 16,18 varies and is not constant. In this simulation, due to the variation of the current and electrical resistance in the stages of the FBW, volumetric heat source model with different uniform distribution (thickness of the heated region in the heat source model is assumed to be 5 mm) is used.…”

Section: Governing Equationsmentioning

confidence: 99%

“…Therefore, the heat input at this stage is lower than the first stage. Due to the variation of electrical resistance (R) versus the contact force, 16,17 the influence of the upsetting force on heat source is modeled by using equation Q = VI (i.e. V and I are electrical voltage and current of the FBW machine; R = V/I).…”

Section: Governing Equationsmentioning

confidence: 99%

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Experimental and numerical investigation of the characteristics of flash-butt joints used in continuously welded rails

Ghazanfari

Tehrani

2019

Proceedings of the Institution of Mechanical Engineers, Part F:

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Continuously welded rails are widely used in the Iran railway network, which are generally built using the flash-butt welding process. To accurately model the flash-butt welding process, thermal analysis, and prediction of the welding residual stresses, the influence of upsetting force on the total electrical resistance and a material model with consideration of the influence of temperature on the material properties are included in the numerical modeling. In this paper, numerical and experimental studies, including the finite element method, thermography, metallography, and hardness testing are performed to determine the characteristics of the welded UIC60 rail. By studying the fractured flash-butt welded UIC60 rails, it is shown that the location of the crack initiation and the rail failure in the web and heat affected zone of the welded rails was similar as compared to the maximum tensile residual stress calculated by numerical simulation. According to the numerical and experimental results, it is shown that four key parameters – such as the maximum temperature during the welding process, the total welding time, the upsetting time, and the upsetting force – control the size, microstructure, and the hardness profile of the heat affected zone which directly affects the characteristics and quality of welding.

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Section: Governing Equationsmentioning

confidence: 99%

Section: Governing Equationsmentioning

confidence: 99%

Section: Governing Equationsmentioning

confidence: 99%

Section: Governing Equationsmentioning

confidence: 99%

See 2 more Smart Citations

Experimental and numerical investigation of the characteristics of flash-butt joints used in continuously welded rails

Ghazanfari

Tehrani

2019

Proceedings of the Institution of Mechanical Engineers, Part F:

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“…According to the principle of the RSW process, dynamic resistance can intuitively and compressively reflect the internal variation of parent metals during the process. Because the phase change processes are the main stages in this research, the beginning of the process, when the contact resistance dominates the whole dynamic resistance and the phase changes were very tiny, can be ignored, and then during the metal melting stage, the effect of the contact resistance is very low [5,30,33,34]. Hence, it is consumed that the dynamic resistance equals to the bulk resistance in the following works.…”

Section: Principle Of the Rsw And Proposed Methods For Measuring The Ementioning

confidence: 98%

Online measuring the electrical resistivity of molten nugget of stainless steel in resistance spot welding

Zhou

Shi

Cai

2017

Journal of Manufacturing Processes

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The variation characteristics of electrical resistivity of the parent metal can improve in-depth understanding of the resistance spot welding (RSW) process. According to the characteristic of RSW process and the physical principle of electrical resistivity, a comprehensive mathematical description of the electrical resistivity measurement of the molten nugget can be obtained. Then a series of corresponding experiments, including the RSW operation to obtain the dynamic resistance, online temperature measurement to obtain the electrical resistivity of solid metals and metallurgical analyses to obtain the size of the molten nugget, were sequentially conducted. The results of the electrical resistivity of the molten nugget can be obtained according to relative measurements, calculations and analyses. The work can benefit the establishment of accurate mathematical model for RSW process, and then serve the welding automation, corresponding researches and actual production process.

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Interface Evolution of Solid Oxide Cells between the Electrode and the Interconnect Rib Induced with Applied Current

et al. 2022

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Herein, the interface evolution of solid oxide cells (SOCs) on the interfacial contact resistance (ICR) between the electrode and the interconnect rib at different current densities is quantitatively studied using a stainless steel 430 (SUS430)/(La,Sr) (Co,Fe)O3 (LSCF)/SUS430 sandwich structure. To simulate the actual operation of SOCs, different current densities (200, 400, 600, 800, and 1000 mA cm−2) are applied to the sandwich structure by an external power supply and a DC electronic load. Experimental results show that, under an isothermal condition for 1012 h and a thermal cycling condition for 15 times, ICR is smaller when the current density is increased. This phenomenon may be due to the softening of the oxide film on the SUS430 interconnect rib and an increase in the contact area between the SUS430 interconnect rib and the electrode LSCF. Additionally, the microstructure, surface roughness, and contact theory are analyzed in detail. The results indicate that interface contact between the electrode and the interconnect rib may be improved with suitable applied current. This work provides the understanding of possible interface evolution of SOCs induced with applied current.

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A review of electrical contact resistance modeling in resistance spot welding

Cited by 55 publications

References 38 publications

Experimental and numerical investigation of the characteristics of flash-butt joints used in continuously welded rails

Experimental and numerical investigation of the characteristics of flash-butt joints used in continuously welded rails

Online measuring the electrical resistivity of molten nugget of stainless steel in resistance spot welding

Interface Evolution of Solid Oxide Cells between the Electrode and the Interconnect Rib Induced with Applied Current

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