Resistance element welding of magnesium alloy and austenitic stainless steel in three-sheet configurations

Manladan, Sunusi Marwana; Zhang, Y.; Ramesh, S.; Cai, Yangchuan; Ao, Sansan; Luo, Zhen

doi:10.1016/j.jmatprotec.2019.116292

Cited by 23 publications

(10 citation statements)

References 18 publications

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“…The industrial implementation of the process was also required to carefully consider the electrode misalignment with the rivet to prevent possible arcing through the material adjacent to the rivet. REW technology was employed to join 1.5 mm-thick AZ31 Mg alloy to two 0.7mm-thick 316 L ASS sheets using different joint configurations 27) . 3D Digital Image Correlation(DIC) method was also employed to measure the out-of-plane deformation and strain distribution in the axial direction during the lap-shear test.…”

Section: Microstructure Analysismentioning

confidence: 99%

“…It was difficult, however, to maintain mechanical properties for the misalignment between the rivet and electrodes with a 6mm electrode diameter for the rivet. Manladan et al 27) studied Mg alloy/ASSs REW joints in multi-sheet configurations. It could be revealed that the nugget size at the rivet/austenitic stainless-steel interface was lower than that at the austenitic stainless steel/austenitic stainless and therefore the latter mainly influenced the failure mode transition.…”

Section: Introductionmentioning

confidence: 99%

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An Overview of Resistance Element Welding with Focus on Mechanical and Microstructure Joint and Optimization in Automotive Metal Joints

Shim

Park²,

Kim

2023

J Weld Join

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As lightweight automotive structures improve fuel efficiency and reduce carbon dioxide emission, they have garnered extensive attention. Vehicle mass reduction, which is a key problem for next generation eco-friendly vehicles, can significantly increase mileage. Hence, industries have committed to replace conventional materials with lightweight materials, such as advanced high strength steel. Additionally, automotive industries are hindered by challenges in the field of joining technology. A novel welding technology called resistance element welding (REW), which is an appropriate thermal-based joining method, was developed recently for joining hybrid materials with other structural steel grades. In this study, the state of the art joining and the process characteristics for dissimilar metal joints have been presented because related studies show limited investigation in this area. Following by the state of them, the principal and welding quality of REW, experimentally and numerically, are reported to give comprehensive information on the current practices and research interest related to technologies. Finally, extensive work was concentrated on portional joining optimization techniques to improve different materials.

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Section: Microstructure Analysismentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

An Overview of Resistance Element Welding with Focus on Mechanical and Microstructure Joint and Optimization in Automotive Metal Joints

Shim

Park²,

Kim

2023

J Weld Join

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“…S.M. Manladana et al [31] in their paper concluded that conventional RSW is not suitable for joining Mg alloy/ASSs in multi-sheet configurations, but REW has the potentials of being a reliable technique for joining Mg alloy and ASS sheets in three-sheet configurations. In the paper of the author S.M.…”

Section: State Of Art In the Field Of Resistance Spot Welding (Rsw) A...mentioning

confidence: 99%

“…Since the PF (TF) sustained higher load and is more complex, it is characterized further. During lap-shear tests, due to the eccentricities in the load path, out-of-plane deformations referred to as secondary bending occur [31]. As shown in Figure 6b, the Al alloy sheet experienced secondary bending.…”

Section: Tensile-shear Static Testmentioning

confidence: 99%

Microstructure and Fatigue Properties of Resistance Element Welded Joints of DP500 Steel and AW 5754 H22 Aluminum Alloy

et al. 2022

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The modern concept of lightweight design (LW) requires the application of different materials in one structure (multi-material structures). The structure of different materials has a good perspective for application in the automotive and aerospace industries but only if it is possible to achieve a quality joint between different materials. The most used technology for joining different materials in the automotive industry is Resistance spot welding (RSW). Due to different mechanical, physical, and chemical properties, the joining of different materials by RSW technology does not provide a quality joint, and accordingly, alternative technologies for joining different materials have emerged. Resistance element welding (REW) was developed to enable joint of different materials. This paper presents the welding of AW 5754 H22 Al alloy (1.0 mm-thick) and DP500 steel (1.5 mm-thick) using novel REW. The peak load, absorption energy, microstructure, microhardness and fatigue strength of the REW joint has been investigated. The joint of the same materials has been done also using conventional RSW to compare some results. The results that will be presented in this paper show that that REW can achieve reliable joining of the two materials at relatively low welding currents compared to RSW. Using REW process with a significantly lower welding current, satisfactory mechanical characteristics of the weld joint can be achieved, so peak load is between 2300–2500 N, displacement is between 2.5–3 mm and the absorption energy is between 3.3–5.7 J. REW joints showed fatigue strength with the fatigue limit of 882 N.

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“…Stainless steels are widely used in aerospace, automotive, and chemical industries due to their high strength, good oxidation resistance, and corrosion resistance [ 1 , 2 , 3 , 4 ]. With the rapid development of technology and industry, welding and joining are applied to make complex stainless steel structures in order to meet pluralistic usage requirements [ 5 , 6 , 7 , 8 ]. Stainless steel joints can be widely found in core panels, heat exchangers, and metal supports which are more and more used in buildings, automobile exhaust systems, and fuel cells [ 9 , 10 , 11 , 12 ].…”

Section: Introductionmentioning

confidence: 99%

Interfacial Microstructure and Mechanical Properties of 1Cr18Ni9Ti/1Cr21Ni5Ti Stainless Steel Joints Brazed with Mn-Based Brazing Filler

Chen

Chen²,

Yang³

et al. 2022

Materials

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The problem of stainless steel brazing is still the focus of scientific research. In this work, the Mn-based brazing filler was used to braze 1Cr18Ni9Ti and 1Cr21Ni5Ti stainless steel. The typical microstructure of the 1Cr18Ni9Ti/1Cr21Ni5Ti joint was analyzed in detail, and the interface structure of the joint was determined to be 1Cr18Ni9Ti/Mn(s, s)/1Cr21Ni5Ti. The brazing temperature and holding time were shown to have a great influence on the microstructure of the brazed joint. The tensile strength of brazed joints first increased and then decreased with the rising of the brazing temperature and the holding time. The maximum tensile strength was 566 MPa when the joints were brazed at 1125 °C for 15 min. The diffusion of Mn and Cr was an important factor affecting the quality of the joints. The diffusion distances of Mn and Cr at different brazing temperatures and holding times were measured, and the diffusion activation energy and diffusion coefficient were achieved by the Arrhenius equation.

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Resistance element welding of magnesium alloy and austenitic stainless steel in three-sheet configurations

Cited by 23 publications

References 18 publications

An Overview of Resistance Element Welding with Focus on Mechanical and Microstructure Joint and Optimization in Automotive Metal Joints

An Overview of Resistance Element Welding with Focus on Mechanical and Microstructure Joint and Optimization in Automotive Metal Joints

Microstructure and Fatigue Properties of Resistance Element Welded Joints of DP500 Steel and AW 5754 H22 Aluminum Alloy

Interfacial Microstructure and Mechanical Properties of 1Cr18Ni9Ti/1Cr21Ni5Ti Stainless Steel Joints Brazed with Mn-Based Brazing Filler

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