Evaluation of heat transfer within numerical models of resistance spot welding using high-speed thermography

Brizes, E.; Jaskowiak, J.; Abke, Tim; Ghassemi-Armaki, Hassan; Ramírez, Antonio J.

doi:10.1016/j.jmatprotec.2021.117276

Cited by 13 publications

(11 citation statements)

References 10 publications

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“…8,9 At present, the welding workstations applied on a large scale in factories rely on pre-programed programs to control industrial robots, welding power sources and workholding fixtures, which lack flexible adaptation to cope with different types of products, and likewise lack real-time adjustment of quality control and welding parameters during the welding process. [10][11][12][13] In this paper, according to the welding mechanism of aluminum alloy galvanized steel resistance spot welding, the industrial robot system, welding power supply, pneumatic actuator, welding machine, cooler, trimmer, software control system and online welding monitoring sensor are integrated to design the intelligent welding system of aluminum/galvanized steel resistance spot welding, to improve the level of resistance spot welding intelligence, and combined with the simulation and SEM (Scanning Electron Microscope) analysis, to analyze the effect of the shape of the electrode cap on the welding performance of the joints, obtains the optimal welding process parameters, and then achieves good welding results.…”

Section: Introductionmentioning

confidence: 99%

Research on online intelligent welding system based on resistance spot welding of aluminum galvanized steel

Chen,

Liu

2024

Advances in Mechanical Engineering

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The article follows a resistance spot welding system, which integrates a six-axis industrial robot, power supply, pneumatic actuator, welder, cooler, trimmer, software control system, welding analyzer, force feedback sensor and welding fixture to realize monitoring of welding quality and real-time adjustment of welding parameters. Taking the resistance spot welding of 6 series aluminum alloy and DC06 galvanized steel as a study, four groups of electrode combinations, 16-6/16-6, 16-10/16-10, 16-7/16-10, and 16-5/16-16 (steel side/aluminum side), are selected for simulation and analysis, and the electrodes are optimized with the simulation results. By selecting the optimal electrode combination to carry out experiments and analyzing the influence of welding current and welding time on the joint performance, the average pulling shear force of the aluminum alloy steel resistance spot weld head is finally realized to exceed the average pulling shear force of the aluminum alloy aluminum resistance spot weld head, and the fracture is all started from the parent material of the alloy side to achieve the failure of the button, and ultimately a good welding effect is achieved.

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Section: Introductionmentioning

confidence: 99%

Research on online intelligent welding system based on resistance spot welding of aluminum galvanized steel

Chen,

Liu

2024

Advances in Mechanical Engineering

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“…Nonetheless, the computed simulation cannot directly recreate the LME cracking during the RSW welding cycles as the conditions required to initiate and propagate LME cracking location are not well known. 10,11…”

Section: Introductionmentioning

confidence: 99%

“…Subsequent studies related to the H-RSW process revealed that RSW process parameters for the H-RSW setup, such as weld current and electrode force, had to be adjusted to replicate full-section RSW (F-RSW). 11,13 However, there exists a lack of understanding about the optimised condition for H-RSW. 11,14–16 The existing studies neither consider parameter optimisation for H-RSW, nor the effect of welding parameters on thermal cycle, which is critical to LME cracking during RSW.…”

Section: Introductionmentioning

confidence: 99%

“…11,13 However, there exists a lack of understanding about the optimised condition for H-RSW. 11,14–16 The existing studies neither consider parameter optimisation for H-RSW, nor the effect of welding parameters on thermal cycle, which is critical to LME cracking during RSW. Leading to the impact of process parameter combinations on the thermal cycle remaining unexplored.…”

Section: Introductionmentioning

confidence: 99%

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Half-sectioned spot weld parameter optimisation for liquid metal embrittlement analysis in advanced high-strength steels

Kim,

Shojaee,

Sherepenko

et al. 2024

Science and Technology of Welding and Joining

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Half-section welding has been proposed as a method to observe nugget growth throughout the resistance spot welding process. Some past studies used this technique as an in-situ monitoring approach to analyse the cracking behaviour during welding. However, there is a lack of understanding regarding the half-sectioned welding parameters, which critically impacts the liquid metal embrittlement cracking index. This study optimised half-sectioned welding parameters for liquid metal embrittlement crack analysis by developing process maps that compare the half-sectioned and full-section processes. It was found that the liquid metal embrittlement crack located at the weld shoulder can correlate to the temperature gradient in the heat-affected zone. This study proposes half-sectioned welding as a viable technique for liquid metal embrittlement analysis.

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“…[7][8][9][10] The use of FEA tool to analyse the heat transfer in spot welding of Usibor 1500 steel was done, and the thermography method was used to calculate the temperature with the help of an infrared camera during the experimentation. 11 The effect of heat inputs on carbon steel joint characteristics was studied along with the effect of MIG welding parameters. They reported that heat input during joint fabrication significantly alters the geometry of the fusion zone and HAZ, which in turn significantly alters the microstructure.…”

Section: Introductionmentioning

confidence: 99%

Investigation of heat input effects on the joint characteristics of CMT welded Aa6061 sheets

Selvamani

Bakkiyaraj²,

Balasubramanian

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part C:

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Cold Metal Transfer (CMT) arc welding is an updated version of the GMAW process, in which heat input is significantly reduced due to the push-pull action of filler wire feeding during welding. The aluminium alloy sheets are welded by the CMT arc welding process using different heat input levels in this research work. The temperature distribution during welding is experimentally measured with the help of an infrared thermometer, and finite element analysis (volumetric heat source model) is used to predict the temperature distribution, and these results are equated. The influence of heat input on joint characteristics such as bead geometry, microhardness variation, microstructure analysis and tensile properties is also being investigated experimentally. The temperature study reveals that the results of numerical modelling for temperature distribution using various heat inputs were very close to the experimental condition, with a less significant difference ±5. In addition, the well-controlled heat input at 210 J/mm was attributed to eradicating porosity, which was confirmed by Non-destructive evaluation, macrostructure and microstructure analysis. As a result, the joint produced a better tensile strength of 241 MPa due to the achievement of fine grain refinement of 17 µm in the weld zone, reduced heat affect zone, and 6.45% volume fraction of Mg2Si particles. The intercept length of 18.937 microns is measured as the average value, and the misorientation angle of 25.2922 was also found as the average in the fusion zone, which is more significant when compared to the base metal value of 20 μm.

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Evaluation of heat transfer within numerical models of resistance spot welding using high-speed thermography

Cited by 13 publications

References 10 publications

Research on online intelligent welding system based on resistance spot welding of aluminum galvanized steel

Research on online intelligent welding system based on resistance spot welding of aluminum galvanized steel

Half-sectioned spot weld parameter optimisation for liquid metal embrittlement analysis in advanced high-strength steels

Investigation of heat input effects on the joint characteristics of CMT welded Aa6061 sheets

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