Characteristics of electrode wear in resistance spot welding dual-phase steels

Zhang, Xinquan; Chen, G.L.; Zhang, Y.S.

doi:10.1016/j.matdes.2006.10.025

Cited by 68 publications

(32 citation statements)

References 3 publications

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“…9 and 10, it was observed that galvanized steel sheets welded with RSW which had approximately the same fracture toughness and energy release rates had lower critical crack size compared to ungalvanized ones. This situation can be explained in the studies of Zhang, Müftüoğlu and Keskinel literature (Müftüoğlu and Keskinel, 2007;Zhang et al, 2008).…”

Section: Discussionmentioning

confidence: 95%

An experimental study on fracture toughness of resistance spot welded galvanized and ungalvanized DP 450 steel sheets used in automotive body

Sevim

2016

REVMETAL

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ABSTRACT:The purpose of this study is to determine fracture toughness of Resistance Spot Welded (RSW) Dual Phase (DP) steels. RSW of galvanized and ungalvanized DP 450 steel sheets was carried out on spot welding machine. Fracture toughness of RSW joints of galvanized and ungalvanized DP 450 steel sheets was calculated from tensile-shear tests. New empirical equations were developed using Least Squares Method (LSM) between energy release rate, fracture toughness and critical crack size depending on the relationship between hardness and fracture toughness values. Results indicated that fracture toughness of joints welded by using RSW increased exponentially while the hardness decreased. In addition, fracture toughness and energy release rate of RSW galvanized DP 450 steel sheets were lower compared to RSW ungalvanized DP 450 steel sheets which had approximately the same hardness. RESUMEN:Estudio experimental sobre la resistencia a la fractura de los aceros de resistencia soldada por puntos DP 450, láminas de acero galvanizado y sin galvanizar utilizados en la estructura del automóvil. El objetivo de este estudio es determinar la tenacidad de fractura de los aceros dual (DP) soldados por puntos de resistencia (RSW). En la máquina de soldadura por puntos se realizó la soldadura de láminas de acero DP 450 galvanizado y sin galvanizar. A partir de los ensayos de tracción-cizallamiento, se calculó la tenacidad a la fractura de las uniones del acero DP 450 galvanizado y sin galvanizar. Aplicando el método de mínimos cuadrados (LSM) se desarrollaron nuevas ecuaciones empíricas entre el porcentaje de energía liberada, la tenacidad de fractura y el tamaño de grieta crítica en función de la relación entre los valores de tenacidad de fractura y de dureza. Los resultados indicaron que la tenacidad de fractura de las uniones soldadas por RSW aumentó exponencialmente, mientras que la dureza disminuyó. Además, el porcentaje de energía liberada de las láminas de acero DP 450 galvanizadas y soldadas fueron menores que en el caso de las láminas sin galvanizar a valores iguales de dureza.PALABRAS CLAVE: Aceros dual (DP); Fatiga; Resistencia soldada por puntos (RSW); Tenacidad a la fractura

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Section: Discussionmentioning

confidence: 95%

An experimental study on fracture toughness of resistance spot welded galvanized and ungalvanized DP 450 steel sheets used in automotive body

Sevim

2016

REVMETAL

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“…The zinc from the coating also alloys with the metal of the electrode caps which causes non-uniform pitting of the electrode tip. Figures 4 and 5 show a comparison between a new electrode tips and used ones, which shows the degraded edges of the tip faces [10].…”

Section: Electrode Cap Wearmentioning

confidence: 99%

An online real time ultrasonic NDT system for the quality control of spot welding in the automotive industry

Athi

Wylie

Cullen

et al. 2009

J. Phys.: Conf. Ser.

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Abstract.Resistance spot welding is the main joining technique used for the fabrication of body-in-white structures in the automotive industry. The quality of the welds depends on the profile of the spot welding electrode cap. The increased use of zinc coated steel in the industry increases wear rate of the caps, making quality control more difficult. This paper presents a novel online real time ultrasonic NDE system for resistance spot welding which evaluates every weld as it is formed. SEM results are presented to show the alloying of the electrode caps.

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“…While there were less than 2000 welds in RSW of coated steels, there were 1000 welds in RSW of aluminum alloy [5,6]. Zhang et al [7] shown that there was no nugget formed at 1200 welds for welding DP600 steel. Electrode wear is the main factor that affects the service life of electrode, and it is hard to be controlled and will influence welding quality seriously [8].…”

Section: Introductionmentioning

confidence: 99%

“…Researches of electrode wear mainly concentrated on the electrode service life and electrode failure form [7,16]. After welding a certain number of spot welds, there is no nugget formed because of electrode wear, and the electrode should be replaced or ground.…”

Section: Introductionmentioning

confidence: 99%

Effects of electrode tip morphology on resistance spot welding quality of DP590 dual-phase steel

Wang

Hua

Wang

et al. 2015

Int J Adv Manuf Technol

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Electrode pitting (EP) and electrode tip diameter enlargement (ETDE) are the two major representations of electrode wear, which lead to the change of electrode tip morphology and have significant impacts on the resistance spot welding (RSW) quality. In order to analyze the effects of electrode tip morphology on RSW quality of DP590 dual-phase steel, the RSW finite element (FE) model is developed to predict the nugget shape and size, whose reliability is verified by experimental observation. Tensile-shear tests are carried out to illustrate the failure behaviors. Three nugget shapes and two failure modes are obtained from different conditions of electrode tip morphology. The results show that EP morphologies produce incomplete fusion at the center of the workpieces' faying surface, while ETDE morphologies reduce the nugget sizes. Both obvious EP and ETDE morphologies resulted in a decline of lap shear fracture load (LSFL).

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Characteristics of electrode wear in resistance spot welding dual-phase steels

Cited by 68 publications

References 3 publications

An experimental study on fracture toughness of resistance spot welded galvanized and ungalvanized DP 450 steel sheets used in automotive body

An experimental study on fracture toughness of resistance spot welded galvanized and ungalvanized DP 450 steel sheets used in automotive body

An online real time ultrasonic NDT system for the quality control of spot welding in the automotive industry

Effects of electrode tip morphology on resistance spot welding quality of DP590 dual-phase steel

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