Mechanical properties of spot welding machines and the effects on weld quality

Sato, Toshiki; Katayama, Joichi

doi:10.1080/09507118809451132

Cited by 4 publications

(4 citation statements)

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“…Satoh and Katayama 36 showed that the moving mass and friction characteristics of the electrode head assembly influenced electrode life. The extent to which life was affected was found to depend on the configuration of the secondary arms of the welding machine.…”

Section: Pedestal Machinesmentioning

confidence: 99%

Review of resistance spot welding of steel sheets Part 2 Factors influencing electrode life

Williams¹,

Parker²

2004

International Materials Reviews

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The factors influencing the formation and growth of the weld nugget in resistance spot welding have been highlighted in Part 1 of this review. While various techniques based on theoretically derived models have been used for the control of weld growth, very few have found widespread application in any production control philosophy. The application of artificial intelligence techniques has proved only partially successful in overcoming the problems encountered. A limiting factor in manufacturing using spot welding is the life of the welding electrodes. A short life necessitates frequent electrode dressing or changing, resulting in lower production rates and higher costs. Also, weld quality is more variable towards the end of the life of an electrode, particularly when welding coated steels. Electrode deterioration causes growth of the electrode tip diameter, which has been shown to be dominant in determining the deterioration in weld quality in production operations. The process of electrode wear has been studied extensively, and metallurgical features such as recovery and recrystallisation of the electrode material, surface alloying, pitting and erosion have been highlighted as determining the rate of electrode growth. However, the relative contributions of these to the overall growth mechanism have not been fully evaluated. Further studies would be beneficial to deriving a solution to the problem. Production variables which influence electrode life include the start welding conditions and electrode tip diameter. The type and design of the welding machine also determine the electrode life, important parameters being (i) the mechanical characteristics of the electrode head assembly defined in terms of the force-time relationship developed on applying the welding force (frictional effects and machine rigidity are important in this context) and (ii) secondary transformer configuration, e.g. series, push-pull, indirect and parallel welding. It has been shown that electrode growth can be overcome by dressing/machining the electrode back to its original diameter at predetermined intervals. However, this procedure has been shown to be limited by the amount of available material which can be removed from the electrode tip before adversely influencing its strength. Alternative approaches have been investigated which indicate that electrode growth can be accommodated by increasing the welding current at predetermined intervals throughout the life. Optimisation of the current stepping program is essential if maximum benefits are to be achieved. This is difficult in practice, but a welding current program based on the gradient of the dynamic weldability lobe can give acceptable results. It is proposed that benefits could be realised by the development of an 'intelligent stepper' in which the current step would be triggered by a feedback signal. Preliminary work using voltage, energy or resistance based measurements has shown promise, although it is probable that a multiparameter based approach may be necessary.

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Section: Pedestal Machinesmentioning

confidence: 99%

Review of resistance spot welding of steel sheets Part 2 Factors influencing electrode life

Williams¹,

Parker²

2004

International Materials Reviews

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show abstract

“…5 They assumed that improvement of the spot weldability of new steels depends not only on parameters but also on the type of machine. Special attention was given to the mechanical properties of the machine.…”

Section: Effect Of Mechanical Properties Of the Welding Machine On Wementioning

confidence: 99%

Mechanical properties of resistance (especially spot and projection) welding machines∗

Lipa

1992

Welding International

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“…1a. According to [4], upper structures of the welding machines are much stiffer than the lower structures. Machine stiffness affects welding processes and weld quality like the expulsion.…”

Section: Introductionmentioning

confidence: 99%

“…Many researchers have used different sensors to collect various signals that can indirectly reflect weld quality, such as voltage, current, dynamic resistance, electrode force, electrode displacement [3,4,6,11]. By comparing the measured signals with desired signals, these methods can assess the weld quality.…”

Section: Introductionmentioning

confidence: 99%

Dynamic behavior investigation of spot welding machines and its influence on weld current range by modal analysis

Gomes

Viéville

Durrenberger

2016

J Braz. Soc. Mech. Sci. Eng.

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Mechanical properties of spot welding machines and the effects on weld quality

Cited by 4 publications

References 0 publications

Review of resistance spot welding of steel sheets Part 2 Factors influencing electrode life

Review of resistance spot welding of steel sheets Part 2 Factors influencing electrode life

Mechanical properties of resistance (especially spot and projection) welding machines∗

Dynamic behavior investigation of spot welding machines and its influence on weld current range by modal analysis

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