Correlating Electrode Degradation with Weldability of Galvanized BH 220 Steel during Electrode Failure Process of Resistance Spot Welding

Abstract

Electrode degradation in continuous resistance spot welding process of BH 220 steel was evaluated by electrode life test, and weldability tests were conducted by geometry features measurement, mechanical property analysis, and electrode diameter measurement with 88 or 176 weld intervals. The analysis of weld geometry shows that the HAZ width, nugget diameter, and nugget area tend to decrease rapidly, while the nugget height tends to firstly increase with the weld repetitions till the welding heat input becomes too small to form the valid nugget. The peak load shows a rapid downward trend, while failure energy and maximum displacement slightly increase till the 176th weld and then decrease. The cavities and pores in the nugget mainly appear after the 176th spot weld. The electrode diameter increases during welding. The reason for the increase in electrode diameter may be that the contact area between the electrode and BH 220 steel sheets becomes smaller in the welding process, which causes the continuous sticking phenomenon between the electrode and the BH 220 steel sheets. In the absence of alloying, the edge of the electrode is geometrically deformed, while Cu-Zn-Fe alloying occurs in the area in contact with the BH 220 steel sheet.