Optimal Design of Square Weld Nut by Taguchi Method and FE Analyses in Nut Projection Welding

Ha, Sangun; Han, Giyeol; Murugan, Siva Prasad; Park, Yeong-Do; Lee, Hyungyil

doi:10.3795/ksme-a.2019.43.6.409

Cited by 1 publication

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“…Therefore, it is perfectly applied to copper and copper alloys resistance welding, due to the generally high conductivity of these materials [11]. Recently, many studies on RPW have been reported, including its physical mechanism [10][11][12], parameters optimization [13][14][15][16][17][18][19][20][21][22], microstructure characterization [20][21][22][23][24][25], and numerical process simulation [16,26]. Wehle et al [10] revealed that projection welding can be accounted for in the solid-state welding process, where the intimate weld interface is formed under plastic deformation at elevated temperatures and surface diffusion which enables re-arrangement of the interface to perfectly fit.…”

Section: Introductionmentioning

confidence: 99%

Microstructure and Properties of Phosphorus Bronze/Brass Joints Produced by Resistance Projection Welding

Lai

Zhang²,

Sheng

et al. 2023

Coatings

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In this work, we fabricated lap joints between embossed projection phosphorus bronze and flat brass through resistance projection welding (RPW). The experimental results indicated that the bronze projection moves into the softer brass without being deformed during the welding process. The tensile shear loads of the joint reached a maximum value of 273.6 N at a welding current of 5.5 kA. Under this circumstance, a reaction layer, including a columnar crystal solidification layer and a diffusion layer, is formed at the interface beside the boundary of bronze. The EDS line scan shows an elemental transition diffusion layer of about 1.5 μm between the H62 brass columnar crystal and XYK-6 phosphorus bronze. The fracture occurred on the XYK-6 side, passing through the bump instead of the welding interface, resulting in intactness of the welding interface. The results revealed that resistance projection welding is an effective method for welding copper alloys, suggesting the bright prospects of this technology in welding electrical parts.

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