Influence of Welding Parameters of Resistance Spot Welding on Joining Aluminum with Copper

Sar, Mohammed Helan; Ridha, Munaf Hashim; Husain, Imad M.; Barrak, Osamah Sabah; Hussein, Sabah Khammass

doi:10.2478/ijame-2022-0029

Cited by 6 publications

(3 citation statements)

References 17 publications

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“…Figure 19. Tensile shear force for similar and dissimilar RSW joint as compared to Refs [46], [63], [64] The dissimilar RSW may be chosen for its specific properties, even if joint strength is not necessarily being improved, as it can offer other benefits, such as electrical conductivity. The specimens for the spot after the tensile shear test failed in full pullout failure mode [66].…”

Section: Tensile Shear Testmentioning

confidence: 99%

Investigating Spot Weld Fatigue Failure with Experimental and Finite Element Analysis Methods

2024

jjmie

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Resistance spot welding (RSW) is the most commonly used method for joining sheet metals structures in the automotive industry. The cyclic loading conditions on RSW joints can lead to fatigue failure, hence, affecting their reliability and durability. The comprehension of the fatigue strength for the RSW is very critical, especially for the dissimilar RSW joints. This study presents analyses to characterize the fatigue behavior of these joints. Therefore, the crack propagation, and fatigue life under specific loading conditions have been studied. The fatigue strength of similar aluminum Al-1050, and dissimilar copper with aluminum Cu-Al RSW joints was examined experimentally and numerically. The lap-sheet materials were spot welded using optimum welding parameters to ensure a consistent range for the produced weld nugget. In this work, the experimental test rig has been designed and established to have an axial fatigue load. The high cycle fatigue tests were performed, and the P-N curves were obtained. The work was analyzed numerically using finite element (FE) analysis, in conjunction with experimental results. Aluminum sheet joint has the highest fatigue limit as compared to dissimilar Cu-Al joints. The crack growth rate of the similar RSW joint is slower than those of dissimilar joints because it has higher stress intensity factor (SIF). The coefficients of the Paris' constants, C and m, have been determined.

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Section: Tensile Shear Testmentioning

confidence: 99%

Investigating Spot Weld Fatigue Failure with Experimental and Finite Element Analysis Methods

2024

jjmie

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“…Copper (Cu) and aluminum (Al) offer superior mechanical qualities, low weight construction, and outstanding thermal and electrical conductivity. Hence, the electric vehicle sector uses them (19).…”

Section: Introductionmentioning

confidence: 99%

Mechanical behavior and failure mechanism of resistance spot welded Aluminum and Copper joint used in the lightweight structures

Fakhri,

Al-Mukhtar,

Mahmood

2024

Diagnostyka

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Recently, dissimilar metals have found applications in the process of resistance spot welding (RSW), particularly within the electric vehicle industry. Notably, copper and aluminum have gained significant importance in these sectors due to their advantageous characteristics for the industry requirements. The mechanical behavior of these materials is essential to maintaining structural integrity. The study aims to estimate the mechanical behavior of dissimilar RSW joints and optimize welding parameters for Cu-Al joints. Hence, understanding the joining processes in the electric vehicle industry to design reliable components. Combining different types of materials, such as T2-grade commercially pure copper sheets and aluminum AA1050 with the same thickness of 1 mm has been welded. The determination of optimal welding conditions takes into account material thicknesses and types. Through tensile-shear testing, welding parameters that yield maximal joint strength were identified. Using Minitab 19 software, the Taguchi method helped achieve optimized welding parameters. The hardness, fracture characteristics, and weld strength have been investigated. Hardness measurements were conducted across the nugget thickness and surface, offering insights into potential failure modes. The welding process involves the transition to a liquid state for the aluminum components, resulting in the formation of intermetallic compounds. Consequently, crack initiation was observed within the aluminum segments, leading to a plug-out fracture mechanism. In contrast, copper exhibits superior strength and hardness compared to aluminum, where increased hardness correlates with heightened strength. The discrepancy in hardness, especially the lower values observed on the aluminum side, caused fractures to appear within the heat affected zone (HAZ). Subsequently, this fracture propagated until pull-out failure was realized. The study revealed that dissimilar joining of Cu and Al resulted in an ultimate tensile stress of 26 MPa, while similar joining of copper showcased a strength of 98 MPa. Additionally, the symmetric join in aluminum exhibited a strength of 93 MPa. The maximum tensile shear force is equal to 512 N at a maximum welding current of 14000 A. The pull-out failure mode occurs in the Cu-Al RSW joint. The maximum hardness was noted in the fusion zone (FZ). Relevant literature sources have supported and confirmed these outcomes.

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“…The higher the stress used, the higher the value of the shear stress strength. When the pressure or welding time is long, the value of the shear stress strength is higher and if the welding time is not constant, the welding results will be damaged [8]. It takes sufficient heat input to form a good nugget structure so as to produce maximum joint strength.…”

Section: Introductionmentioning

confidence: 99%

The Effect of Spot Welding Parameters for Dissimilar Material Mild Steel and Galvanizes Steel on Nugget Size and Mechanical Strength

Hayat,

Al Muslim,

Aminy

2022

EPI-IJE

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The objective of this research was to analyze the effect of spot welding parameters on the size of the weld nugget and the maximum shear strength on dissimilar material mild steel and galvanized steel. The Taguchi and ANOVA methods were used to determine the welding parameters’ contribution to joint quality. Experimental design using Minitab-19 software with Taguchi method of 3 level 3 factor with L27 runs. Specimen size and dimensions were made using ASTM D1002 standard, with a plate thickness of 0.8 mm. Taguchi analysis S/N ratio data mean for weld nugget diameter with three levels of current used, 4 kA, 6 kA, and 8kA, shows the most influential on the diameter of the weld nugget was at 8 kA. The three levels of welding time used, 2s, 4s, and 6s, show the most influential on the diameter of the nugget the weld was at the third level for 6 seconds. It found that there was no significant difference in the size nugget at the three electrode pressure levels of 30 Ppsi, 40 Psi, and 50 Psi. Based on the tensile test and Taguchi analysis, the lowest shear strength was found in a weld nugget size of 3.15 mm at a welding current of 4 kA, a welding time of 2 seconds, an electrode pressure of 30 Psi, with a shear tensile strength of 300.19 N. Along with an increase in the size weld nugget correlated to an increase of shear strength. The highest shear tensile strength was found in the nugget size of 4.16 mm, with a welding current of 8 kA, welding time of 2 seconds, electrode pressure of 50 Psi, with a shear tensile strength of 3383.43 N. From the ANOVA, it found that the three factors of spot welding parameters were used, the most influential parameter in the formation of weld nuggets was welding current with a contribution of 84.86% then followed by welding time with a contribution of 14.86% and electrodes force with a contribution of 0.13%. Then from the three factors of spot welding parameters that were used the most influential parameter on the maximum shear tensile strength was the welding current with a contribution of 95.86 % then followed by welding time with a contribution of 0.52% and electrodes force with a contribution of 0.05%.

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Influence of Welding Parameters of Resistance Spot Welding on Joining Aluminum with Copper

Cited by 6 publications

References 17 publications

Investigating Spot Weld Fatigue Failure with Experimental and Finite Element Analysis Methods

Investigating Spot Weld Fatigue Failure with Experimental and Finite Element Analysis Methods

Mechanical behavior and failure mechanism of resistance spot welded Aluminum and Copper joint used in the lightweight structures

The Effect of Spot Welding Parameters for Dissimilar Material Mild Steel and Galvanizes Steel on Nugget Size and Mechanical Strength

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