An Overview of Resistance Element Welding with Focus on Mechanical and Microstructure Joint and Optimization in Automotive Metal Joints

Shim, Ji Yeon; Park, Min Woo; Kim, Ill Soo

doi:10.5781/jwj.2023.41.1.4

Cited by 4 publications

(3 citation statements)

References 56 publications

(95 reference statements)

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“…REW is a process that integrates the principles of thermal and mechanical bonding between the insert and the bottom material. The 'force and form-locking' establishes a joint between the insert and the top material [38]. Interlayers such as zinc, nickel, and Al-Mg alloys are used to improve the weldability of composite materials with the use of RSW [39].…”

Section: Use Of Interlayers and Metal Insertsmentioning

confidence: 99%

A Review on the Recent Trends in Forming Composite Joints Using Spot Welding Variants

Arumugam,

Pramanik

2024

J. Compos. Sci.

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Traditional resistance spot welding (RSW) has been unsuccessful in forming quality composite joints between steel– or aluminum–polymer-based composites. This has led to the development of spot welding variants such as friction stir spot welding (FFSW), ultrasonic spot welding (USW), and laser spot welding (LSW). The paper reviewed the differences in the bonding mechanisms, spot weld characteristics, and challenges involved in using these spot welding variants. Variants of RSW use series electrode arrangement, co-axial electrodes, metallic inserts, interlayers, or external energy to produce composite joints. FFSW and USW use nanoparticles, interlayers, or energy directors to create composite spot welds. Mechanical interlocking is the common composite joint mechanism for all variants. Each spot welding variant has different sets of weld parameters and distinct spot weld morphologies. FFSW is the most expensive variant but is commonly used for composite spot weld joints. USW has a shorter welding cycle compared to RSW and FFSW but can only be used for small components. LSW is faster than the other variants, but limited work was found on its use in composite spot weld joining. The use of interlayers in FFSW and USW to form composite joints is a potential research area recommended in this review.

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Section: Use Of Interlayers and Metal Insertsmentioning

confidence: 99%

A Review on the Recent Trends in Forming Composite Joints Using Spot Welding Variants

Arumugam,

Pramanik

2024

J. Compos. Sci.

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“…Owing to the increasing severity of global warming, studies have been conducted to enhance energy efficiency and reduce fuel consumption in various industrial fields to meet the environmental regulations [1][2][3][4][5][6][7] . For instance, commercializing electric vehicles has become one of the most important objectives in the automotive industry to completely eliminate carbon dioxide emissions [8][9][10] .…”

Section: Introductionmentioning

confidence: 99%

Effect of Cr on the Hot Ductility of Austenitic Fe-Mn-Al-C Lightweight Steel

Jeong,

Moon,

Park

et al. 2024

J Weld Join

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In this study, a hot ductility test was performed for Fe-30Mn-10.5Al-0.9C-Cr austenitic lightweight steels. The test was carried out through a commercial Gleeble simulator at a heating rate of 350 °C/sec and cooling rate of 50 °C/sec, with a stroke rate of 50 mm/sec. Microstructural analysis for understanding the hot ductility behavior was conducted through optical and scanning electron microscopy. The lightweight steels exhibited similar hot ductility behavior in accordance with temperature despite the addition of Cr. The experimental results indicated that the κ-carbide precipitation had an insignificant influence on the hot ductility test. However, ductility at low temperature was induced by slip mechanism, while dynamic recrystallization had significant influence at high temperatures during the on-heating thermal cycle. In the on-cooling thermal cycle, the melted and re-solidified grain boundaries decreased the overall ductility, exhibiting the same tendency as that observed in the on-heating test.

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“…To meet these requirements, the utilization of advanced highstrength steels (AHSSs) is increasing. These steels offer high strength and are engineered with improved formability, enabling the fabrication of vehicle structures using thinner sheets [3][4][5]. Transformation-induced plasticity (TRIP) steels, in particular, provide an outstanding combination of strength and ductility, making them an attractive material for producing lighter and more crash-resistant vehicles [6,7].…”

Section: Introductionmentioning

confidence: 99%

Liquid Metal Embrittlement Cracking in Uncoated Transformation-Induced Plasticity Steel during Consecutive Resistance Spot Welding

Kim,

Manladan,

Mahmud

et al. 2023

Metals

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In the automotive production line, a single pair of electrodes is employed to produce hundreds of consecutive welds before undergoing dressing or replacement. In consecutive resistance spot welding (RSW) involving Zn-coated steels, the electrodes undergo metallurgical degradation, characterized by Cu-Zn alloying, which impacts the susceptibility to liquid metal embrittlement (LME) cracking. In the present investigation, the possibility of LME crack formation in uncoated TRIP steel joints during consecutive RSW (involving 400 welds in galvannealed and uncoated TRIP steels) was investigated. The results have shown that different Cu-Zn phases were formed on the electrode surface because of its contamination with Zn from the galvannealed coating. Therefore, during the welding of the uncoated TRIP steel, the heat generated at the electrode/sheet interface would result in the melting of the Cu-Zn phases, thereby exposing the uncoated steel surface to molten Zn and Cu, leading to LME cracking. The cracks exhibited a maximum length of approximately 30 µm at Location A (weld center) and 50 µm at Location B (shoulder of the weld). The occurrence and characteristics of the cracks differed depending on the location as the number of welds increased due to the variation in Zn content. Type A cracks did not form when the number of welds was less than 280. Several cracks with a total length of approximately 30 μm were suddenly formed between 280 and 400 welds. On the other hand, type B cracks began to appear after 40 welds. However, the number and size of these exhibited inconsistency as the number of welds increased. Overall, the results have shown that small LME cracks can form even in uncoated steels during consecutive welding of Zn-coated and uncoated steel joints.

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An Overview of Resistance Element Welding with Focus on Mechanical and Microstructure Joint and Optimization in Automotive Metal Joints

Cited by 4 publications

References 56 publications

A Review on the Recent Trends in Forming Composite Joints Using Spot Welding Variants

A Review on the Recent Trends in Forming Composite Joints Using Spot Welding Variants

Effect of Cr on the Hot Ductility of Austenitic Fe-Mn-Al-C Lightweight Steel

Liquid Metal Embrittlement Cracking in Uncoated Transformation-Induced Plasticity Steel during Consecutive Resistance Spot Welding

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