An Exploratory Study on Resistance Spot Welding of Titanium Alloy Ti-6Al-4V

Abstract

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.

Prediction of welding properties of solder joints based on machine learning

“…We can also use VB to encapsulate the naive Bayes formula in CATIA. API, but the construction process will involve the processing of data standardization, which also needs to calculate the mean and variance, so we can directly use Scikit-learn [10].…”

Effect of Spot-Welding Parameters on the Strength of the Weld of Metal Sheets

“…The Taguchi analysis revealed that the electrical current (22%) and welding time (17%) are the most effective factors on nugget diameter. Fatmahardi I et al (2021) carried an experiment using the Taguchi L9 method to determine the optimum level of weld joint strength in titanium alloy Ti-6Al-4V. The result showed that in the fusion zone, the combination of high heat input and rapid air cooling…”

Optimisation of spot-welding process using Taguchi based Cuckoo search algorithm

“…In the recent past, researchers employed the conventional statistical design of experiment (DOE) based techniques like the Taguchi method, Response Surface Methods (RSM), Grey Relational Analysis (GRA), etc to optimize spot-welding process parameters. Attempts to optimize tensile strength for spot-welded joints of Titanium alloy [Bozkurt and Çakır (2021), Fatmahardi et al (2021)], aluminum alloys [Raheem, (2021)], dissimilar materials combining steels and composites [Neystani et al (2019)], steels [Tyagi et al(2022), Kumar et al (2021), Ebrahimpour et al (2021)], have been computed through the Taguchi method [Bozkurt and Çakır (2021), Fatmahardi et al (2021), Neystani et al (2019), Tyagi et al(2022), Kumar et al (2021)] and RSM [Raheem, (2021), Ebrahimpour et al (2021)]. But such processes generally involve high mathematical complexity among operating parameters and possible experimental noise.…”

“…The literature survey indicates applications of several conventional statistical methods including Taguchi, RSM, etc to optimize the resistance spot welding processes [Bozkurt and Çakır (2021), Fatmahardi et al (2021), Neystani et al (2019), Tyagi et al (2021), Kumar et al (2021)] Raheem, (2021), Ebrahimpour et al (2021)]. However, those optimization processes have inherent limitations to stuck into local minima often resulting in faulty optimized output for multimodal problems.…”