Numerical and experimental study on nugget formation in resistance spot welding for three pieces of high strength steel sheets

Ma, Ninshu; Murakawa, Hidekazu

doi:10.1016/j.jmatprotec.2010.07.025

Cited by 57 publications

(21 citation statements)

References 16 publications

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“…This heat generated melts the metal at both the surfaces. At the same point, the pressure exerted from the copper electrodes compresses the melt materials and fuses the surfaces of the metal into a single volume called nugget [2]. The nugget diameter depends on the electrode diameter, weld current, and the weld time.…”

Section: Introductionmentioning

confidence: 99%

Studies on the influence of process parameters on the AISI 316L resistance spot-welded specimens

Jagadeesha

Jothi

2015

Int J Adv Manuf Technol

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Resistance spot welding (RSW) is a popular welding process employed for joining sheet metals typically in automobile and aerospace industries. RSW is conventional but not obsolete as it addresses the desirable characteristics of energy efficiency, narrow heat-affected zone (HAZ), simplicity, and automation that make it the first choice of manufacturers. In recent days, there is a perpetual demand for spot welding owing to its suitability for joining components especially in biomedical applications. Austenitic stainless steel of grade AISI 316L, a biocompatible material with extraordinary features and global suitability, caters to several industrial dimensions. In this research paper, an attempt is made to experimentally investigate the quality of the weld prepared by resistance spot welding of austenitic stainless steel type 316L of equal thickness (2.0+2.0 mm). Experimental trials based on design of experiments (DOE) are conducted by varying the process parameters such as electrode tip diameter, welding current, and heating time and subsequently measure the nugget size and shape which governs the strength and bond integrity of the resistance spot welds. Subsequently, a coupled structural-thermo-electric analysis is performed to analyse the transient temperature field for predicting the nugget formation during RSW of 316L stainless sheet using a 2D axisymmetric finite element (FE) model. FE-based model of RSW process is developed using ANSYS Parametric Design Language (APDL) module available in FE package, ANSYS. Thermo-physical interactions like heat transfer through the Joule effect, the effect of latent heat of fusion, and the thermal and electrical contact conductance are considered while developing the FE-based model. A good coherence is achieved between numerical predictions of nugget shape and experimental spot-welded results. Finally, the welded specimens are subjected to destructive testing and metallurgical characterizations to evaluate its strength and quality.

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Section: Introductionmentioning

confidence: 99%

Studies on the influence of process parameters on the AISI 316L resistance spot-welded specimens

Jagadeesha

Jothi

2015

Int J Adv Manuf Technol

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“…De esta forma, al incrementarse el calor de aporte, también se incrementó la temperatura en la zona de la soldadura, produciendo que el cinc interactuara más rápido, debido a que el cinc en estado líquido difunde 500 veces más rápido que cuando se encuentra en estado sólido [16].…”

Section: Figura 16 Carga Máxima De Los Ensayos De Tensiónunclassified

Evaluación del Deterioro de los Electrodos al Incrementar el Número de Pulsos del Tiempo de Soldadura en Aceros IF y HSLA Galvanizados y la Afectación de las Propiedades Mecánicas en los Puntos de Soldadura

et al. 2017

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Este es un artículo publicado en acceso (Open Access) abierto bajo la licencia Creative Commons Attribution NonCommercial, que permite su uso, distribución y reproducción en cualquier medio, sin restricciones siempre que sin fines comerciales y que el trabajo original sea debidamente citado.Recibido: 12 Jun., 2016 Aprobado: 14 Nov., 2016 E-mails: miguel.f.pamanes@gmail.com (MFDP), smald@uaz.edu.mx (SIMR)Resumen: La soldadura de resistencia por puntos, es el método más importante en la industria ensambladora de carrocería autoportante o monocasco debido a su automatización, su rapidez, flexibilidad de soldar piezas con forma compleja, es económico debido a que no requiere metal de aporte, además de la posibilidad de aplicar pulsos de precalentamiento y de postcalentamiento para mejorar la soldabilidad del punto de soldadura, el cual se define como la capacidad de la estructura de proporcionar protección adecuada a los pasajeros contra lesiones en caso de una colisión, principalmente depende de la integridad y rendimiento mecánico del botón de soldadura. Para extender la vida de los vehículos se producen aceros galvanizados. Sin embargo, los recubrimientos de cinc han incrementado la dificultad de soldabilidad, siendo necesarias corrientes mayores en el proceso, pues se presenta una menor resistencia en la interfase de soldadura debido a una mejor conductividad eléctrica. Este trabajo investiga el efecto del galvanizado en la disminución de la vida de los electrodos, por esta razón, se deduce una pérdida en las propiedades mecánicas en los botones de soldadura conforme se aumenta el número de puntos de soldadura. El objetivo principal del presente estudio es correlacionar el desgaste de los electrodos con las propiedades mecánicas de los botones de soldadura. El procedimiento experimental consiste en hacer 1.000 puntos de soldadura; para cada vigésimo quinto punto de soldadura a partir del primero, los cuales se examinaron por estereoscopia, ensayos de dureza, ensayos de desbotonamiento y ensayos de tensión al corte. En el desgaste del electrodo, se evaluó la cara por impresión en papel carbón, microscopia óptica y espectroscopia de rayos-X (EDX). Palabras-clave:Acero IF; Acero HSLA; Galvanizado; Soldadura de resistencia por puntos; Deterioro de electrodos; Propiedades mecánicas de los puntos de soldadura. Assessment of Impairment of the Electrodes by Increasing the Number of Pulses of the Welding Time on IF and HSLA Steels Galvanized and Involvement of the Mechanical Properties in the Nuggets WeldsAbstract: Resistance welding points, is the most important method in the assembly industry of unibody because of its automation, which is defined as the ability of the structure to provide adequate protection to passengers against injury from a collision, mainly depends on the mechanical performance of the weld nugget. To extend the life of vehicles produced coated steels. However, zinc coatings have increased the difficulty of weldability due to it being higher currents needed in the process because less resistance is ...

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“…(8) where is mass density, is specific heat capacity, is thermal conductivity coefficient, is temperature, and is voltage. Specific heat capacity at melting temperature is given by (9) [20].…”

Section: Thermal Equationsmentioning

confidence: 99%

“…Finite element models used to analyze RSW process are not readily usable to consider shunting effect, however, there are several RSW FEM studies on simulation of thermal and electrical distribution (Huh [8], Archer [9], Greenwood [10], and Tsai [11]), prediction of the electrical and thermal contact properties and contact radius (Loulou et al [12], Okuda [9], and Shen et al [13]), growth of nugget and thermal deformations (Nied [14], Gould [15]), and electrical-thermal-mechanical analysis (Zhang [16] and Kim et al [17]). Although most of these studies have included thermal, electrical and mechanical aspects of the RSW process, the asymmetry of shunting configuration due to existence of shunting (previous) nugget prohibits the use of 1D or 2D axisymmetric models.…”

mentioning

confidence: 99%

Experimental and numerical analysis of shunting effect in resistance spot welding of Al2219 sheets

Vardanjani¹,

Araee²,

Senkara³

et al. 2016

Bulletin of the Polish Academy of Sciences Technical Sciences

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Abstract. Few aspects of shunting effect have been studied so far. Shunting effect in resistance spot welding (RSW) occurs when the electrical current passes through the previous spot welds. Value of this current depends mostly on distance, number, and size of previous spot welds. This will cause some dimensional and metallurgical changes in welding nugget as well as heat affected zone (HAZ). In this study, shunting effect of RSW is considered by finite element method (FEM) and the results are compared to experiments performed on aluminum alloy 2219. Weld spacing together with welding current and time are considered to discover the effect of shunting current in the final quality of nugget. A three factor experiment design has been performed to find the significance of factors and interactive effects, as well as finite element model verification. Electrothermal and mechanical interactions are considered in the FEM. Experimental and numerical solutions have yielded similar results in terms of welding nugget properties. Asymmetry in electrical potential, temperature, stress distribution and geometry of shunted nugget is predicted and verified directly or indirectly. Intense effect of shunting current on nugget height, asymmetric growth of heat affected zone (HAZ) toward previous welding nugget, as well as concentration of alloying elements along grain boundaries are also discovered. Kim et al. [17]). Although most of these studies have included thermal, electrical and mechanical aspects of the RSW process, the asymmetry of shunting configuration due to existence of shunting (previous) nugget prohibits the use of 1D or 2D axisymmetric models.In this paper, shunting effect in RSW is investigated using FEM and the results are compared with experiments on AA2219. The influence of welding distance, current and time are investigated to consider shunting effect in final quality of the nugget. Experiments are designed inside the weldability range, while the results are compared to results of FEM after verification. have included thermal, electrical and mechanical aspects shunting configuration due to existence of shunting (prev 2D axisymmetric models. MethodsIn this paper, shunting effect in RSW is investigated using with experiments on AA2219. The influence of welding d investigated to consider shunting effect in final quality of inside the weldability range, while the results are compar

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Numerical and experimental study on nugget formation in resistance spot welding for three pieces of high strength steel sheets

Cited by 57 publications

References 16 publications

Studies on the influence of process parameters on the AISI 316L resistance spot-welded specimens

Studies on the influence of process parameters on the AISI 316L resistance spot-welded specimens

Evaluación del Deterioro de los Electrodos al Incrementar el Número de Pulsos del Tiempo de Soldadura en Aceros IF y HSLA Galvanizados y la Afectación de las Propiedades Mecánicas en los Puntos de Soldadura

Experimental and numerical analysis of shunting effect in resistance spot welding of Al2219 sheets

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