Contact resistance prediction of zirconium joints welded by small scale resistance spot welding using ANN and RSM models

Al-Sabur, Raheem; Slobodyan, Mikhail; Chhalotre, Sanjay; Verma, Manoj

doi:10.1016/j.matpr.2021.04.431

Cited by 10 publications

(5 citation statements)

References 20 publications

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“…As well as the hollow electrode tends to raise the current limit and produces substantially larger nugget sizes by allowing the molten metal to expand into the electrode's hole instead of fading to the sides and improving the weldability properties [23]. Secondly, the hollow electrode geometry produces relatively more heat by changing the contact resistance and current density distribution compared with the conventional electrode [24]. which in turn, leads to an increase in the nugget size and improves the strength of the spot welds.…”

Section: Effect Of Hollow Electrode Dimensions On Spot Welding Strengthmentioning

confidence: 99%

“…Furthermore, in resistance spot welding, the electrode and thermal resistance of the workpiece has a significate effect on heat dispersion in the workpiece's environment. So the contact resistance between the bulk beside the contact resistance between the workpiece and the electrode represented the total electrical resistance that affects the welding properties [9]. Based on the Joule law, the use of electrodes as the contact tip workpiece and joining unit during resistance spot welding has a significant impact on the wear behavior and contracting which is affected by electrode force [10].…”

Section: Introductionmentioning

confidence: 99%

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The Effect of Electrode Geometry and Pre-heating Treatment on Resistance Spot Welding Strength

Hassan

Lafta

2023

ETJ

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The min. and max. improvement in tensile shear strength was (103-140)%.• The min. and max. improvement in the torsional strength was (103-149)%. • The preheating treatment of the lab joint leads to improving the tensile and torsional strengths of the weld joint. • The preheating treatment showed an improvement range of (115-141)% in tensile shear strength and (124-171)% in torsional strength.Resistance spot welding (RSW) is one of the most significant and common metal joining methods used in industries. The present paper discusses the comparative performance of resistance spot welding electrodes of nontraditional design with the traditional one of 8 mm contact diameter in welding a 1.5 mm thick low carbon steel sheet used in automobile structural bodies and bridges. The modified electrode tip surface center was machined to have three different holes of 2, 3, and 4 mm depth and three different diameters of 2, 4, and 6 mm producing nine different hollow electrode dimensions. As well as the influence of pre-heating temperature on the mechanical properties of the weld joint was investigated by considering the other main parameters of welding time, current, and force are constant. The shear tensile test and torsion test examinations are carried out to investigate the mechanical properties. Also, to interrupt the results, a macrograph examination was conducted to determine the nugget size formation. The results show that the increase or decrease in the strength of the weld joint is greatly influenced by the proper selection of the modified electrode geometries. Also, the results indicated that the maximum improvement in shear tensile strength and torsional strength is about 140% and 150% compared to the traditional one. Furthermore, pre-heating processes helped decrease the contact resistance at the faying surfaces and improve the weld tensile strength and torsional strength to about 141% and 171% at 200℃. Moreover, improvement may be achieved by slightly increasing pre-heating temperatures

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Section: Effect Of Hollow Electrode Dimensions On Spot Welding Strengthmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

The Effect of Electrode Geometry and Pre-heating Treatment on Resistance Spot Welding Strength

Hassan

Lafta

2023

ETJ

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“…Heat input is critical in welding operations as it directly affects the weld, heat‐affected zone (HAZ), and grain size. [ 11,12 ] Ramachandran et al [ 13 ] observed that as heat input rises, the microstructure of acicular ferrite (AF) and bainitic ferrite in the coarse‐grained HAZ of fusion‐welded HSLA steel transformed into a combination structure of polygonl ferrite, granular bainite (GB), and martensite‐austenite (M‐A) constituents. The former exhibits greater resilience, while the latter is more brittle.…”

Section: Introductionmentioning

confidence: 99%

Effect of Heat Input on the Metal Microstructure and Mechanical Properties of Q960 High‐Strength Steel Solid Core Welding Wire

Zhu,

Min,

Xiao

et al. 2024

steel research int.

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The self‐developed Q960 high‐strength steel solid wire with different heat input is welded by MIG welding to solve the problem of insufficient low‐temperature toughness of Q960 steel weld. The effect of heat input on the microstructure and mechanical properties of butt welding deposited metal is studied in depth. The results show that the microstructure of deposited metal is composed of granular bainite (GB), degenerate upper bainite (DUB), martensite (M), and acicular ferrite (AF). DUB and M play key roles as strengthening phases, whereas GB and AF serve as primary toughening phases. Elevated heat input leads to a progressively rougher microstructure in the deposited metal. AF and DUB increase first and then decrease, GB increases and M decreases slightly. The inclusions conducive to AF nucleation are mainly composed of oxides of Mn, Si, Ti, and Mn sulfide with sizes between 100 and 500 nm. At a 14 kJ cm−1 heat input, the complex phase microstructure effectively refines the grain, and the high‐angle grain boundaries and ferrite interlocking structure optimize the strength and toughness balance of the deposited metals. The tensile strength measures 958 MPa, with the highest elongation at 19% and an average impact toughness of 50 J at −40 °C.

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“…[17,18] At present, there is limited research available in the open literature regarding the RSW of Zr-alloy triple sheets, mainly focusing on the welding of Zr-alloy tubes, the measurement and stability of contact resistance, and small-scale RSW. [19][20][21][22][23][24][25][26] Compared with the two-layer plate, there is an additional contact interface in the three-layer plate, which changes the proportion of heat DOI: 10.1002/adem.202400380…”

Section: Introductionmentioning

confidence: 99%

Weld Growth Mechanism, Microstructure, and Mechanical Properties of Resistance‐Spot‐Welded Joint of R60702 Zirconium‐Alloy Triple Sheets

Li,

Yang,

et al. 2024

Adv Eng Mater

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Triple sheets of R60702 zirconium (Zr) alloy were joined together using the resistance spot welding (RSW) process in this study. The nugget formation mechanism and microstructure of the weld joint in three equal‐thickness sheets of R60702 Zr alloy were studied. The results revealed that the initial nugget formed at the top of the intermediate sheet, and subsequently expanded both radially and axially until a complete nugget was formed. The fusion zone (FZ) exhibited a martensitic microstructure, while the heat affected zone (HAZ) consisted of two regions: coarse grain heat‐affected zone (CGHAZ) and fine grain heat‐affected zone (FGHAZ). The hardness in the FZ was higher than that of the HAZ and the base metal (BM). Furthermore, the tensile shear force and fracture mode of the weld nuggets were also studied. The weld joints exhibited a maximum tensile‐shear load of 5.7 kN under the following welding parameters: welding current of 14 kA, welding time of 150 ms, and welding force of 3.6 kN. Three failure modes were identified interface fracture (IF), partial button fracture (PBF), and button fracture (BF).This article is protected by copyright. All rights reserved.

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Contact resistance prediction of zirconium joints welded by small scale resistance spot welding using ANN and RSM models

Cited by 10 publications

References 20 publications

The Effect of Electrode Geometry and Pre-heating Treatment on Resistance Spot Welding Strength

The Effect of Electrode Geometry and Pre-heating Treatment on Resistance Spot Welding Strength

Effect of Heat Input on the Metal Microstructure and Mechanical Properties of Q960 High‐Strength Steel Solid Core Welding Wire

Weld Growth Mechanism, Microstructure, and Mechanical Properties of Resistance‐Spot‐Welded Joint of R60702 Zirconium‐Alloy Triple Sheets

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