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Published: 7 July 2024
Last updated: 7 July 2024

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1

Vishwakarma, Shailesh Kumar, Anurag Shrivastava, and Sharmistha Singh. "Optimization of Resistance Spotwelding Parameters Using Taguchi Method." International Journal of Emerging Research in Management and Technology 6, no. 7 (June 29, 2018): 196. http://dx.doi.org/10.23956/ijermt.v6i7.211.

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Resistance spot welding (RSW) is a major sheet metal joining process in many industries, such as the automobile, domestic appliances, and space craft fabrication. It is one of the oldest of the electric welding processes in use by industry today. Furthermore, other metal-to-metal connections, such as wire-to-wire joints in the electronics industry, are accomplished by resistance spot welding. Application-specific measures, such as the diameter of the welding spot, define the quality of the joint. The weld is made by a combination of heat, pressure, and time parameters. As the name implies, it uses the resistance of the materials to the flow of electric current that causes a localized heating in the parts to be joined. Understanding of physical mechanisms for easily manipulating and controlling weld qualities in advance is extremely important. This paper represents the optimization of various parameters of resistance spot welding. The experimental studies have been conducted under varying pressure, welding current, pressure, and welding time parameters. In this investigation the quality characteristic (tensile strength and nugget diameter) parameters have been considered using Taguchi Method. The experimental studies have been carried out by varying welding currents, welding pressure and weld times for joining two sheets. The results of the investigation indicate the welding current to be the most significant parameter controlling the weld tensile strength as well as the nugget diameter. The contribution of welding current, holding time and pressure to tensile strength are 61%, 29%, 4% respectively and the contribution of these parameters to nugget diameter are 81%, 1.7%, 17% respectively. Relationship graphs have been plotted between tensile strength and nugget diameter with parametric variations according to orthogonal array.
2

Chang, Xu, Jie Liu, Guang Wei Fan, and Ren Long Tao. "Study on Microstructure and Fracture Morphology of 2205 Duplex Stainless Steel Resistance Spot Welds." Materials Science Forum 804 (October 2014): 289–92. http://dx.doi.org/10.4028/www.scientific.net/msf.804.289.

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Fracture morphologies, microstructures and mechanical properties of the spot welded joints on 2205 duplex stainless steel (2205DSS) were studied by using three-phase inverter resistance welding machine with the welding currents of 6.4kA, 7.4kA, 9.5kA and 11.6kA, the welding pressures of 0.5MPa, 0.6MPa and 0.7MPa, and the welding time of 200ms. The results show that the macroscopic fracture fashion of 2205DSS spot welding joints are mainly button fracture and joint fracture, and the microstructures and mechanical properties of 2205DSS spot welding joints have the best performance with the welding current of 9.5kA, the welding time of 200ms and the welding pressure of 0.6MPa.
3

Zhou, Wei Min. "The Electrical Contact Resistance in Resistance Welding Evaluated by Gleeble Testing Machine." Materials Science Forum 575-578 (April 2008): 753–56. http://dx.doi.org/10.4028/www.scientific.net/msf.575-578.753.

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Electrical contact resistance is an important parameter in resistance welding. In this article, a Gleeble 3500 thermal-mechanical testing machine was employed to measure the contact resistance. The machine is equipped with a special electrical resistance measuring system. The contact resistance is experimentally investigated for welding low carbon steel to themselves. A detailed work was carried out to investigate the influence of pressure, temperature on the contact resistance of low carbon steel. The experimental results show that the contact resistance decreases when pressure or temperature increases.
4

Kajiwara, Ryoichi, Satoshi Kokura, Yuzo Kozono, Tomohiko Shida, and Takao Funamoto. "Investigation of welding phenomena in resistance pressure welding using insert material." QUARTERLY JOURNAL OF THE JAPAN WELDING SOCIETY 3, no. 4 (1985): 683–90. http://dx.doi.org/10.2207/qjjws.3.683.

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5

Yu, Yan, Feng Xue Wang, and Zai Dao Yang. "Study on Resistance Spot Welding Technology and Properties of TRIP800 High Strength Steel Sheet." Advanced Materials Research 391-392 (December 2011): 661–65. http://dx.doi.org/10.4028/www.scientific.net/amr.391-392.661.

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A series of spot welding technology, joint mechanical properties and microhardness test analysis of TRIP800 high strength steel were researched. Based on these experiments and analysis, effect of spot welding parameters such as welding current, welding time and electrode pressure on joint mechanical properties were explored. The relevant spot welding parameters of TRIP800 high strength steel of spot welding were recommended, such as welding current is7.5~8.0KA, electrode pressure is 450 kgf and welding time is 20cyc. Welding electrode should be to ensure that as much as possible and clean the surface,to avoid welding current and welding time is too high or too long, as well as forging lack of power, to prevent the occurrence of welding defects.
6

Han, Lijun, Wenchao Yu, and Lei Jia. "Study on Welding Parameter Model of Resistance Spot Welding of Body-in-white Al Alloy Plate." Journal of Physics: Conference Series 2706, no. 1 (February 1, 2024): 012020. http://dx.doi.org/10.1088/1742-6596/2706/1/012020.

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Abstract In this paper, the welding parameter model of resistance spot welding (RSW) of body-in-white(BIW) Al alloy plate was studied in details, and the key welding parameters that influence the RSW quality are analysed in-depth. Based on the concept of equivalent plate thickness (SV ), simplification of nugget volume and thermodynamic theories, combined with the properties of Al alloy, the mathematical models of welding current, pressure, time were established through production data and test verification. These models reflect the relationship between key welding parameters and equivalent plate thickness. The welding current and pressure are linear with SV , and the expressions are different when SV is greater than 2. For welding pressure, there exist two critical curves according to the different yield strength of welding materials. The yield of the material lies in between and pressure can be chosen between two critical curves. The welding time is directly linear to the actual thickness of the plate. Actual welding parameters can be obtained by the models and least test, which is very important for decision of welding parameters rapidly.
7

Zhang, Jun Ping, Yi Feng, Lei Feng Song, Guang Yao Wang, and Qing Sheng Jin. "Research on Resistance Spot Welding Property of Hot-Stamping Quenched Steel Sheets." Advanced Materials Research 1063 (December 2014): 120–25. http://dx.doi.org/10.4028/www.scientific.net/amr.1063.120.

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22MnMoB hot-stamping quenched steel sheets were well welded together by power frequency spot welder with optimization of relevant welding parameters in this paper. According to the experiment results of welding spatter, maximum shearing force and the size of nugget, the effects of welding current, welding time and electrode pressure on weld property were advanced. The results show that while welding current, welding time and electrode pressure are respectively set as 6.0~6.5kA, 0.5~0.7s and 4~7kN, the weld exhibits good mechanical property. The nugget diameter appears approximate linear relationship with mechanical property of weld and determines the fracture model of welds. The novel hot stamping steel sheets exhibit good welding property. The optimizing welding parameters can be used to instruct the practical production.
8

Zhang, Xiaoqi, Lingbo Wei, Guocheng Xu, and Chunsheng Wang. "Connection Status Research of the Resistance Spot Welding Joint Based on a Rectangular Terminal Electrode." Metals 9, no. 6 (June 5, 2019): 659. http://dx.doi.org/10.3390/met9060659.

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Rectangular terminal electrode is adopted in this research to conduct a resistance spot welding (RSW) process on stainless steel plate. The connection status of RSW joints under different welding current, time, and pressure were studied, and revealed how the rectangular terminal electrode shape and its dimensions influence the RSW joint dimensions. The process analysis results showed that the RSW nuggets welded with rectangular terminal electrode are normally elliptical in shape, and the dimensions of the long axis direction and the short axis direction have a certain proportion. As the welding current increases, the nuggets dimensions in long direction increase first and then decrease, and the internal grain structure also varies. As the welding time increases, the nugget size in long direction increase first and then steady and rarely splash occurs. As the welding pressure increase, the nugget dimensions in long direction increase first and then decrease, and the splash easily occurs under large welding pressure. However, when the welding pressure is too small, the unique adjacent double fusion nugget formed. By adopting proper welding parameters, the nugget size and quality can be controlled. This provides an important basis for the application of rectangular terminal electrode in RSW welding process.
9

Georgescu, Bogdan, Dănuţ Mihăilescu, and Marius Cornel Gheonea. "Shear Resistance of Joints Spot Cold Pressure Welding." Applied Mechanics and Materials 657 (October 2014): 251–55. http://dx.doi.org/10.4028/www.scientific.net/amm.657.251.

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The statement from the specialty literature that with the increasing diameter of spot welded by cold pressure decreases the amount of resistance to shear force is due to reporting of the breaking by shear at the circular section of the point. Our experimental research shows that a welded cold joint in spots, correctly done, will be torn off near the weld spot by drawing the point from one of the tins. By reporting the force to the real section of breaking it resulted a constant shear resistance, no matter which the size of the welded point was. Therefore, the approximate theoretical calculation of the breaking force of a cold welded point, correctly executed, can be achieved by knowing the mechanical properties of the metal base and taking into account the real section of the breaking point given by points periphery and the thickness of the panel after deformation. The calculation is encompassing, because due to cold hardening, the real mechanical characteristics are higher.
10

Jin, Zhao, Yafeng Qiu, Hao Yan, Dingbang Xu, and Xiaoming Hou. "Research on the influence of Welding Head using the process on Welding Performance of Spot Welding Machine." Journal of Physics: Conference Series 2396, no. 1 (December 1, 2022): 012019. http://dx.doi.org/10.1088/1742-6596/2396/1/012019.

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Abstract Aiming at alloys commonly used in terminals, this paper studies the method of improving the characterization performance of the spot welding section from the perspective of controlling spot welding process parameters. Using the control experiment, by controlling the welding current, energization time, electrode pressure, and using coolant during welding, the surface structure image and the maximum tensile-shear force curve were obtained, so as to obtain the optimal spot welding process parameters. Then use ANSYS finite element analysis software to simulate the resistance spot welding process, and use the model of the macro morphology, microstructure, hardness distribution, and shear resistance of the spot welding head to verify the optimal welding process parameters of resistance spot welding.
11

Shi, Huajie, Irene Fernandez Villegas, and Harald EN Bersee. "Analysis of void formation in thermoplastic composites during resistance welding." Journal of Thermoplastic Composite Materials 30, no. 12 (September 9, 2016): 1654–74. http://dx.doi.org/10.1177/0892705716662514.

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The process-induced voids during resistance welding of glass fabric-reinforced polyetherimide was investigated. The mechanisms of void formation in adherends, in particular, the residual volatile-induced voids and the fibre de-compaction-induced voids, were analysed. Due to the non-uniform temperature and stress distributions in the joints during welding, a non-uniform void distribution was observed in the joints with more voids generated in the middle of the joints than at the edges. Welding temperature and pressure were shown to have a large influence on void formation. Increasing of welding pressure was shown to effectively reduce the voids, while the residual moisture-induced voids were found more difficult to be eliminated than the fibre de-compaction-induced voids.
12

Bondarenko, O. F. "Coordination of welding pulse parameters with electrode pressure program and electrophysical processes in welding contact." Технология и конструирование в электронной аппаратуре, no. 5-6 (2019): 51–60. http://dx.doi.org/10.15222/tkea2019.5-6.51.

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Resistance welding is an important technological operation for many modern industries, including mechanical engineering, electronics and instrument making. Micro resistance welding is used in producing of micro-structures for critical purposes, such as electronic components, circuits, etc. It is obvious that welded joints in such structures should be characterized by such high quality indicators as the absence of solid metal splashes, burnouts, faulty fusions, and the repetitiveness of dimensions of welding spots, which are achieved by coordinating the parameters of welding current pulses with electrophysical processes in welding contact. Thus, in this paper, the authors analyze electrophysical processes taking place in the welding contact and the effect of the welding current pulse parameters on these processes, in order to mutually coordinate them. This allows specifying the law of pulse power change, which makes it possible to take into account the features of electrophysical processes in the welding contact to the full extent. The smooth rise of the pulse power, obtained according to the exponent law with selection of the optimal exponent n value, provides gradual input of energy required for welding during the most unstable phase of primary contact formation. Due to the flat top of the welding pulse, the constant energy input to the contact is maintained during a rather stable phase of welding core formation. Finally, the smooth pulse fall obtained by selecting the optimal exponent m value of the power change law provides the proper cooling of the welding spot, which guarantees the strength and uniformity of the joint structure. To achieve the best welding quality, the recommendations are given regarding the formation of rise and fall of the pulse, depending on specific welding conditions, parameters of the welded parts and requirements for the obtained joints. The paper shows that it is a useful practice to coordinate the pulse power change law with the program of changing the pressure of the electrodes, and with changing the resistance of the welding zone. The proposed example of coordination between welding pulse power change, welding electrode pressure and electrophysical processes in the welding contact (resistance of the welding zone) is substantiated in terms of the influence of the electrode pressure on the welding process. This practice can provide the highest quality of welded joints and thus the highest quality of the end products manufactured by welding.
13

Wang, Nan Nan, Ran Feng Qiu, Wei Jian Peng, and Hong Xin Shi. "Resistance Spot Welding between Mild Steel and Stainless Steel." Applied Mechanics and Materials 675-677 (October 2014): 23–26. http://dx.doi.org/10.4028/www.scientific.net/amm.675-677.23.

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Mild steel Q235 and stainless steel SUS304 were welded using resistance spot welding with an interlayer of Ni. The mechanical properties of the joint were examined, the effects of welding parameters on the nugget size and tensile shear strength were investigated. Both the tensile shear strength and nugget diameter increased with the increasing of welding current and welding time, whereas they decreased with the increasing of electrode pressure. The results indicate that the tensile shear strength of joint welded by resistance spot welding with a Ni interplayer is higher in comparison with that obtained by conventional resistance spot weling.
14

Kas and Das. "Adaptive Control of Resistance Spot Welding Based on a Dynamic Resistance Model." Mathematical and Computational Applications 24, no. 4 (September 28, 2019): 86. http://dx.doi.org/10.3390/mca24040086.

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Resistance spot welding is a process commonly used for joining a stack of two or three metal sheets at desired spots. Such welds are accomplished by holding the metallic workpieces together by applying pressure through the tips of a pair of electrodes and then passing a strong electric current for a short duration. This kind of welding process often suffers from two common drawbacks, namely, inconsistent weld quality and inadequate nugget size. In order to address these problems, a new theoretical approach of controlling resistance spot welding processes is proposed in this paper. The proposed controller is based on a simplified dynamical model of the resistance spot welding process and employs the principle of adaptive one-step-ahead control. It is essentially an adaptive tracking controller that estimates the unknown process parameters and adjusts the welding voltage continuously to make sure that the nugget resistance tracks a desired reference resistance profile. The modeling and controller design methodologies are discussed in detail. Also, the results of a simulation study to evaluate the performance of the proposed controller are presented. The proposed control scheme is expected to reduce energy consumption and produce consistent welds.
15

Zeidan, Lutfi. "OPTIMIZING THE PROCESS OF RESISTANCE SPOT WELDING FOR 2014 – O ALUMINUM ALLOY SHEET." Diyala Journal of Engineering Sciences 1, no. 1 (September 1, 2008): 46–55. http://dx.doi.org/10.24237/djes.2008.01104.

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There is a strong interest in the use of aluminum alloy sheet for vehicle applications, particularly the body, where resistance spot welding is the principle joining method. The resistance spot welding (R.S.W) quality has a great effected by the process variable such as, welding current, welding time, and electrode pressure beside other variable such as material thickness and type and electrode diameter. In this work the effect of process variable on welding quality was investigated. Trials were conducted on 1.2 mm thick 2014 – O aluminum alloy sheet. The tensile shear strength was used as primary index of welds quality. Experimental investigation show that the best current is 45 KA, best time is 10 cycle, and electrode pressure of 3 KN .
16

Ramdani, Mohammed, Mustapha Benachour, and Mohammed Rahou. "The Effects of Resistance Spot Welding Parameters on the Mechanical Behavior of Stainless Steel." Engineering, Technology & Applied Science Research 13, no. 2 (April 2, 2023): 10501–4. http://dx.doi.org/10.48084/etasr.5019.

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The resistance spot welding process is a promising method for welding thin sheets of similar and dissimilar materials, principally stainless steel. Resistance spot welding is ensured using the combined effect of mechanical pressure and electric current through the thin sheets. In this experimental study, 304L stainless steel sheets were welded by resistance spot welding at various welding parameters. The welding parameters were welding effort, welding time, and welding current. Welding current varied from 10kA to 16kA, welding time varied from 10 to 13 cycles, and welding effort was fixed to 8 bars. The results showed that welding time had little effect on the mechanical properties compared to the welding current. The experimental results also showed that welding current is an important parameter for joining sheets and their mechanical strength. The external aspects of the spots were examined to determine the influence of welding parameters on the welded joints.
17

Medina, D. Y., R. Bermejo, R. T. Hernandez, I. Hernandez, and S. Orozco. "Evaluation of Resistance Spot Welding Conditions Using Experimental Design." MRS Proceedings 1481 (2012): 97–102. http://dx.doi.org/10.1557/opl.2012.1637.

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ABSTRACTThe breaking strength that can withstand solder is known as resistance welding, low resistance welding will cause a failure of the weld. This study optimized the effect of the main variables in a welding steel proceess on the mechanical propierties of the steel like the resistance welding. The main variables studied were electrode, machine, post induction, and dotted pressure. The factors that have the most influence in the resistance welding are the post induction, and the combination of post induction and the raw material.The statistical model used for the evaluation process was an analysis of variance (ANOVA) in a full crossing factorial design 2k with a second order of interaction.
18

Tian, Shuai, Qiaobo Feng, Chunliang Wang, and Rui Zhang. "Optimized designing of process parameters for CP980 steel resistance spot welding based on Orthogonal Test." Journal of Physics: Conference Series 2775, no. 1 (June 1, 2024): 012029. http://dx.doi.org/10.1088/1742-6596/2775/1/012029.

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Abstract Based on the orthogonal experimental design method, taking CP980 steel as the research object and the tensile sheer force of spot-welded joints as the evaluation index, the effect of different process parameters on the welding performance of resistance spot welding was studied with the extreme variance method. The results indicated that welding current had a significant effect on the shear force, followed by electrode pressure, while welding time had the least effect; the optimal welding parameter of the CP980 spot welded joint was that the welding time was 400 ms, the welding current was 9.5 kA, and the electrode pressure was 3.6 kN. The formation of lath martensite during solidification led to a higher hardness in the nugget region, reaching a maximum of 434 HV. The subcritical heat-affected zone formed a softened zone with an average hardness value of 299 HV as a result of welding thermal cycling.
19

Yuan, Bo, Yan Liu, Wenqi Zhang, Zhen Tian, Shan Zhao, and Wenxiong Feng. "Optimal Design of Orthogonal Test for Resistance Spot Welding." Journal of Physics: Conference Series 2459, no. 1 (March 1, 2023): 012112. http://dx.doi.org/10.1088/1742-6596/2459/1/012112.

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Abstract The optimal parameters of the resistance spot welding process are discussed, combined with the development and practice of the automobile manufacturing industry. The value, significance, and basic theory of the resistance spot welding process orthogonal test are summarized, and the importance of the orthogonal test is recognized. Then summarize the orthogonal test specimen and equipment preparation, test design, and finally analyze the orthogonal test to conclude that the optimal parameters of the resistance spot welding process are optimized, that is, the welding time is 9cyc, the electrode pressure is 1600N, and the optimal welding current is It is 11.5kA, which provides a reference for future manufacturing.
20

Zhang, He, Shang Wang, Bingying Wu, Weiwei Zhang, Chunjin Hang, and Yanhong Tian. "Ultrafast Parallel Micro-Gap Resistance Welding of an AuNi9 Microwire and Au Microlayer." Micromachines 12, no. 1 (January 3, 2021): 51. http://dx.doi.org/10.3390/mi12010051.

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Welding between an AuNi9 microwire and Au microlayer is of great importance for fabricating electrical contact structures for high precision inertial devices, satellite slip ring brushes, robots, etc. In this paper, the achievement of parallel micro-gap resistance welding (PMRW) with 200-μm AuNi9 microwires on a 3-μm Au layer was presented. The study on the orthogonal design of the experiment was carried out. The effect of the process parameters (welding current, welding time, and welding pressure) was discussed in reference to the morphologies and tensile force of the joint using range analysis. It is shown that too much or too little heat input will decrease the welding performance. A group of optimized process parameters (0.275 kA welding current, 3 ms welding time, and 28.7 N welding pressure) was obtained. During the welding process, the dynamic resistance of the whole welding system was measured, which can reflect the welding quality. Finite element simulation is utilized to calculate the welding temperature. The highest temperature was located in the center area of the AuNi9 microwire, reaching 1397.2 °C, which is higher than the melting point of AuNi9. By contrast, the highest temperature for the pad was 826.47 °C (lower than the melting point of Au). Hence, under optimized process parameters, a transient interfacial reaction between the liquid AuNi9 microwire and solid Au pad occurred, and the strength of the welded joint reached 5.54 N.
21

Kajiwara, Ryoichi, Tomohiko Shida, Takao Funamoto, Satoshi Kokura, and Yuzo Kozono. "Relation between joint properties and welding conditions in resistance pressure welding of SUS304 stainless steel. Investigation of resistance pressure welding method using insert material. Report 2." QUARTERLY JOURNAL OF THE JAPAN WELDING SOCIETY 5, no. 1 (1987): 59–64. http://dx.doi.org/10.2207/qjjws.5.59.

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22

Zhang, Z. D., Ya Rong Wang, and D. Q. Li. "Expulsion in Resistance Spot Welding of AZ31B Magnesium Alloy." Materials Science Forum 546-549 (May 2007): 443–46. http://dx.doi.org/10.4028/www.scientific.net/msf.546-549.443.

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Expulsion is undesirable during the resistance spot welding due to the weld quality decrease. The expulsion happening during the resistance spot welding of AZ31B magnesium alloy was studied related to the distribution of maximum temperature in the interface due to the existing of contact resistance, and connected with the increased pressure in the nugget due to melting and expansion of liquid metal. The influence of welding parameters on expulsion is presented and discussed in this investigation.
23

Pouranvari, M. "Effect of Welding Parameters on the Peak Load and Energy Absorption of Low-Carbon Steel Resistance Spot Welds." ISRN Mechanical Engineering 2011 (April 12, 2011): 1–7. http://dx.doi.org/10.5402/2011/824149.

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Effect of process variables (electrode pressure, holding time, welding current, and welding time) on low-carbon steel resistance spot welds performance has been investigated in this paper. Failure mode, peak load, and maximum energy obtained in tensile-shear test have been used to describe spot welds performance. Excessive electrode pressure can reduce both peak load and maximum energy, considerably. Holding time does not significantly affect peak load and maximum energy for investigated material. Increasing welding time and welding current to some extent increases both peak load and maximum energy. However, excessive welding time and welding current not only do not increase weld nugget size and peak load, but also decrease maximum energy.
24

Nonomura, Toshiki, Tsuyoshi Kosaka, Tatsuya Kobayashi, Ikuo Shohji, and Muneyoshi Iyota. "Microstructure and Mechanical Properties of A6061/GA980 Resistance Spot Weld." Key Engineering Materials 966 (November 29, 2023): 25–30. http://dx.doi.org/10.4028/p-rue1zd.

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Resistance spot welding was performed on steel and an Al alloy to investigate the microstructural and mechanical properties of the joint. An Al-Mg-Si aluminum alloy A6061 and an alloyed zinc-plated steel sheet GA980 were used as specimens. Resistance spot welding was performed at welding currents of 16 kA, 20 kA, and 22 kA, welding time of 0.24 s, and welding pressure of 5 kN. To investigate the strength of the welds, the tensile shear test and the cross tension test were conducted, and the fatigue test was also conducted. The nugget diameter increased with an increase in the welding current. The tensile shear strength and cross tension strength increased with the increase in the welding current. In the tensile shear fatigue test, interface fracture was observed in the low cycle fatigue region. In the cross tension fatigue test, it was confirmed that the higher the welding current, the better the fatigue properties in the low-cycle fatigue region.
25

Alzahougi, Abdulkarim, Bilge Demir, and Muhammed Elitas. "An Optimization Study on Resistance Spot Welding of DP600 Sheet Steel via Experiment and Statistical Analysis." Engineering, Technology & Applied Science Research 13, no. 4 (August 9, 2023): 11106–11. http://dx.doi.org/10.48084/etasr.5804.

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Resistance Spot Welding (RSW) is widely used in many automotive, boiler, and ship manufacturing industries. Therefore, the optimization and effectiveness of the RSW process are very useful and cost-efficient processes in addition to improving weld quality. This study used various welding parameters to investigate the optimization of the RSW process of Advanced High Strength Steel (AHSS). RSW was carried out using different welding times, currents, and electrode pressure values. Microstructural analysis, nugget formation, and tensile shear test were performed on samples. This study applied the Taguchi method and ANOVA to set up the welding process and optimize its results. Microstructural characterization showed that the weld nugget microstructures had a high-volume fraction of martensite. Using the Minitab software, Taguchi (DOE) and ANOVA on the tensile shear test results showed that welding current is more effective than clamping pressure on the tensile shear load-bearing capacity (TLBC). However, clamping pressure affects the weld current effects on weld performance. Additionally, the TLBC of RSW samples increases, whereas increasing the clamping pressure leads to a decrease in TLBC and nugget dimensions. Consequently, a detailed analysis of the RSW coefficients and their effects led to optimized results.
26

Chirileanu, Marius Ioan, and Diana Antonia Gheorghiu. "Researches about Mechanical Characteristics of some Steels Resistance Spot Welded." Applied Mechanics and Materials 371 (August 2013): 265–69. http://dx.doi.org/10.4028/www.scientific.net/amm.371.265.

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This work studies the influence of resistance spot welding (RSW) process upon the mechanic characteristics of three steel grades: S235JR, galvanized S235JR and austenitic stainless grade 304L. The variable parameter was the welding current. Constant parameters were the pressure (6 bars) and the welding time (5 cycles). Micro hardness and tensile-shear resistance tests were done. Welded joint hardness profile reveal a relative softer nuclei surrounded by the hardest zone and a progressive decrease throughout the heat affected zone (HAZ) to the unaffected material. The shear resistance depends upon the welding intensity as well as metal grade.
27

Pasau, K., N. Salam, A. Y. Aminy, and A. Hayat. "Effect of Welding Time Variation in Resistance Spot Welding on Mechanical Properties of Dissimilar Joints on Mild Steel and AISI 304 Stainless Steel." Journal of Physics: Conference Series 2739, no. 1 (April 1, 2024): 012044. http://dx.doi.org/10.1088/1742-6596/2739/1/012044.

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Abstract Resistance spot welding plays an important role in the automotive industry for working on car bodies or frames. Welding with two different steel materials is used in automotive structures. However, the low strength of the joints of different steel materials is a major problem, limiting the scope of its application. The quality of the welding connection Resistance spot welding is influenced by several factors, namely, time, welding current, and electrode pressure applied during welding and post-welding treatment. In this research, mild steel plate with AISI 304 stainless steel is welded by Resistance spot welding with different variations of welding time, material hardness and tensile testing that will be investigated. The results showed that the highest Rockwell Hardness time was obtained at a welding time variation of 8 seconds with a current of 6000 Ampere was 112.2 so the higher the welding time, the higher the hardness obtained. welding 8 seconds with a welding current of 6000 Ampere obtained a maximum tensile strength of 20.4 kgf/mm2 so the greater the welding current, the tensile strength will increase.
28

Voiculescu, I., V. A. Oprea, and I. M. Vasile. "Case Study About Resistance Projection Welding of Aluminized Steel Parts." Annals of Dunarea de Jos University of Galati Fascicle XII Welding Equipment and Technology 32 (December 31, 2021): 23–29. http://dx.doi.org/10.35219/awet.2021.03.

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Resistance projection welding is a non-polluting mechanized process used to obtain an assembly between similar or dissimilar metallic materials. The main advantages of this welding process are the possibility to achieve many different welded points at the same time and the long life of the electrodes compared to the spot-welding process. The paper analyses the effects of thin aluminium coating existing on mild steel parts of on the correct formation of welding points when assembling moulds for the manufacture of baking bread. From optical and electron microscopy analyses it resulted that some adjacent welded points show an interrupted fusion line, sprinkled with elongated islands of aluminium-rich compounds. The paper presents the effect of changing the values ​​of the welding parameters on the weld spot size, in correlation with the Al-rich inclusions that appear on the weld fusion zone. The best results have been obtained when the welding parameters values were the follows: electrode pressure of 2.6 bar, welding power of 19.18kVA and welding time of 7ms. The problems that occur when electric resistance welding of parts with aluminium coating have been highlighted, being useful for specialists who make products using this welding process.
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Zhang, Guowei, Ting Lin, Ling Luo, Boming Zhang, Yuao Qu, and Bangke Meng. "Multi-Objective Optimization of Resistance Welding Process of GF/PP Composites." Polymers 13, no. 15 (July 31, 2021): 2560. http://dx.doi.org/10.3390/polym13152560.

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Thermoplastic composites (TPCs) are promising materials for aerospace, transportation, shipbuilding, and civil use owing to their lightweight, rapid prototyping, reprocessing, and environmental recycling advantages. The connection assemblies of TPCs components are crucial to their application; compared with traditional mechanical joints and adhesive connections, fusion connections are more promising, particularly resistance welding. This study aims to investigate the effects of process control parameters, including welding current, time, and pressure, for optimization of resistance welding based on glass fiber-reinforced polypropylene (GF/PP) TPCs and a stainless-steel mesh heating element. A self-designed resistance-welding equipment suitable for the resistance welding process of GF/PP TPCs was manufactured. GF/PP laminates are fabricated using a hot press, and their mechanical properties were evaluated. The resistance distribution of the heating elements was assessed to conform with a normal distribution. Tensile shear experiments were designed and conducted using the Taguchi method to evaluate and predict process factor effects on the lap shear strength (LSS) of GF/PP based on signal-to-noise ratio (S/N) and analysis of variance. The results show that current is the main factor affecting resistance welding quality. The optimal process parameters are a current of 12.5 A, pressure of 2.5 MPa, and time of 540 s. The experimental LSS under the optimized parameters is 12.186 MPa, which has a 6.76% error compared with the result predicted based on the S/N.
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Ariyanto, Ariyanto, Iman Pradana A. Assagaf, Rifaldy Ramadhan Latief, Fajar Reski Maulana, Gusrifar Gusrifar, Muh Aqdar Fitrah, and Muhammad Ikhsan. "RANCANG BANGUN PROTOTIPE PREPARASI MATERIAL RESISTANCE SPOT WELDING." Jurnal Rekayasa Mesin 14, no. 2 (August 15, 2023): 725–33. http://dx.doi.org/10.21776/jrm.v14i2.1466.

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The manufacturing process in the automotive industry is in dire need of resistance spot welding machines. Because it was easier to use, highly effective, and effective in functioning. However, there were sometimes still connection problems that were still of poor quality, both nuggets and areas that are subject to electrode pressure. To get a quality welding connection, a machine was needed that was able to carry out good material preparation in the form of sanding, able to set the welding current analogously, able to set the time with an automatic timer, able to apply pressure on the electrode measurably during the welding process. The research aimed to design a prototype of resistance spot welding material preparation that could adequately carry out material preparation and welding using a Bluetooth system connected to a mobile phone. The research methods carried out were as follows: first, designing the machine using Autodesk Inventor software, then the device was made with a focus on material preparation prototypes, then the machine elements were made for the material clamping rail, then the machine elements in the control section using Bluetooth connected to the mobile phone, the machine was tested, then the connection quality testing process was carried out on the tensile testing machine. The results showed that the design results had been made using elbows and iron plates with threaded rails with a length of 650 mm, which became material clamping rail grooves with a drive using window motors controlled by Bluetooth on the Arduino circuit. The test results of welded joints show that the roughness is 0.20 μm which has the highest tensile strength.
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Ariyanto, Ariyanto, Iman Pradana A. Assagaf, Rifaldy Ramadhan Latief, Fajar Reski Maulana, Gusrifar Gusrifar, Muhammad Aqdar Fitrah, and Muhammad Ikhsan. "Prototype of Resistance Spot Welding Material Preparation to Improve the Quality of Welding Joints." International Journal of Engineering Business and Social Science 1, no. 04 (April 24, 2023): 283–89. http://dx.doi.org/10.58451/ijebss.v1i04.58.

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The most improtant manufacturing process in several industries was resistance spot welding. Because it was easier to operate, it was very effective and efficient in operation, but sometimes there were still connection problems that were still of poor quality, both nuggets and areas that experience electrode pressure. The quality of the resistance welded joint was influenced by several factors, namely: preparation of materials, welding time, welding current, electrode pressure applied at the time of welding and treatment after welding. The purpose of this study is to design a material preparation prototype and analyze the test results of the resistance spot welding material prototype. The research method was carried out by designing a prototype of the preparation of resistance spot welding material and analyzing the strength of the best welded joints for the most qualified joints. Data collection was carried out by varying the roughness of the transverse surface of the joint to be tested by selecting the right welding parameters, tensile strength testing, and surface roughness. The results of the design carried out were made used iron plate as a frame with a thickness of 5 mm and using a thread bolt 670 mm long as a rail drive line and the movement of the rail was driven by a power window motor and can be controlled automatically with the help of arduino, Servo motor, and Bluetooth module. The best welding strength was obtained at the roughness of the C600=0.20µm sandpaper where in the sandpaper experiment it was the smoothest.
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Garg, Satish, S. S. Banwait, and Ravneet Kumar. "Optimisation of High Frequency Seam Welding Parameters By Taguchi Method." Asian Journal of Engineering and Applied Technology 2, no. 2 (November 5, 2013): 78–83. http://dx.doi.org/10.51983/ajeat-2013.2.2.661.

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Seam welding is a versatile and most widely used method of fabrication in pipe and tube industries. A seam weld is a series of overlapping resistance spot welds made progressively along a joint by rotating circular electrodes. With the operating conditions becoming more and more stringent and the increased use of seam welded pipe joints in Industrial and domestic pipelines, the improvement in mechanical properties have become increasingly important. In this study, process parameters viz. Welding current, frequency of current, Roll Pressure and weld speed of Therma Tool welding machine were studied at three levels in a reputed company of Northern India by using L9(3)4 orthogonal arrays of Taguchi method to study tensile strength of electric resistance welding of pipes of 15 mm diameter of Class B. “Welding speed” was found to be contributing the most i.e. 45.43% in variation of Tensile strength followed by “roll pressure” which is contributing 22.93%. The parameter “Welding Current” contributing 20.92% and “Weld current frequency” is affecting least to variation being 10.58% of total variation of process. Lower levels of weld speed and Roll pressure, medium level of welding current and higher level of current frequency resulted in improvement in Tensile strength of pipes by 11.8%.
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Dobrzański, Przemysław. "Bonding of High Temperature Thermoplastic Carbon Composites with Resistance Welding Technique." Transactions on Aerospace Research 2018, no. 3 (September 1, 2018): 1–13. http://dx.doi.org/10.2478/tar-2018-0018.

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Abstract The article presents ‘state-of-the art’ on joining fibre reinforced thermoplastic composites with the use of resistance welding technique. Their welding process and potential difficulties connected with the process and quality control of a manufactured element are presented. The structure of a typical thermoplastic composite welding stand was also presented. The main welding technology elements were characterized: structure of the resistance element, implementation of the thermal process and pressure application required for joining materials. The paper also presents the required calibration ranges for a technological process with the use of strength test types SLS, DCB, SBS and nondestructive testing of joint with the ultrasonic method.
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Habib, Lebbal, Reffas S. Ahmed, Berrekia Habib, and Mario Guagliano. "Experimental Study of Spot Weld Parameters in Resistance Spot Welding Process." Mechanics and Mechanical Engineering 22, no. 1 (August 12, 2020): 179–86. http://dx.doi.org/10.2478/mme-2018-0016.

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AbstractResistance spot welding is a comparatively clean and efficient welding process that is widely used in sheet metal joining. This process involves electrical, thermal and mechanical interactions. Resistance spot welding primarily takes place by localized melting at the interface of the sheets followed by its quick solidification under sequential control of water cooled electrode pressure and flow of required electric current for certain duration. In this experimental work the tensile tests and the spot weld diameter were studied. The objectives of this analysis is to understand the physics of the process and to show the influence of the electrical current, weld time and the type material in resistance spot welding process.
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Nirmala Shivram, Padmavat. "Different Welding Processes Using Statistical and Numerical Approaches Using the Fuzzy TOPSIS Method." Journal on Materials and its Characterization 1, no. 1 (September 1, 2022): 46–52. http://dx.doi.org/10.46632/jmc/1/1/6.

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Welding is for two or more parts heat; pressure or Linking is a fabrication process cooling of parts. Welding usually involves metals and Used in thermoplastics, but also in wood can be used. A finished welded joint May be referred to as good material. Welding such as metals, thermoplastics, and/or wood Applying heat or pressure to materials It is a process of joining them together. Cool those down Allow enable the connection. Different Processes and techniques unique to materials required there are some people items that are considered unusable. MIG welding uses an electrode wire and shield gas fed continuously through A lamp held in the hand. A consumable for TIG welding is tungsten uses an electrode, which is a supply line, and Shield through a separate, hand-held filler wire manually injected into the weld pool with gas. Research significance: Welding is two or more parts by heat, pressure, or both together Linking is a fabrication process. Welding is usually in metals and thermoplastics used, but can also be used on wood. The finished welded joint may be referred to as a weld meant. Gas pressure welding joins two base materials in under pressure by heating them with gas contact. Resistance spot welding two Combine the basic ingredients together heating up with heat generated by electrical resistance by conducting current. The basic purpose of welding is within a solid joint combining two elements. Welders in general Work with metal or thermoplastic and durable filler material to hold together are using Skyscrapers in our world, many modern ones like cars, ships, and planes Welding is used to make structures. Mythology: Alternative: Factorial designs, ANNs, GA, and RSM. Evaluation Option: Computational time, Experimental domain, Model developing, Availability in software, Optimization Accuracy level. Result: from the result it is seen that Model developing and is got the first rank whereas is the Availability in software got is having the lowest rank. Conclusion: The value of the dataset for Welding Process in Fuzzy TOPSIS method shows that it results in Model developing and top ranking.
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Wang, Jun, Yun Yan Hu, Hui Xia Wang, and Yu Feng Zhang. "Study on the Numerical Simulation of the Resistance Spot Welding Process of Magnesium Alloy." Advanced Materials Research 189-193 (February 2011): 3431–36. http://dx.doi.org/10.4028/www.scientific.net/amr.189-193.3431.

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Spot welding of magnesium alloy was a complex processes of thermal, electrical, mechanical and metallurgical mutual coupling, meanwhile its’ low melting point, high thermal conductivity, and high linear expansion coefficient increased the welding quality control difficultly. Basing on SYSWELD, a numerical simulation of effects of welding current, welding time, thickness of plate, electrode pressure gauge and size on the nugget shape and welding quality of ZA31B was demonstrated. The relationship between the size of the nugget dimensions and the welding parameters was established by a large number of simulation and experimental study. The experimental results showed that the analogue result was consistent with the test results, and it could be used to guide the actual production.
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Brezinová, Janette, Miroslav Džupon, Marek Vojtko, Ján Viňáš, Ondrej Milkovič, Jakub Brezina, Anna Guzanová, and Dagmar Draganovská. "Application of Cold Metal Transfer Welding for High Pressure Die Casting Mold Restoration." Metals 9, no. 11 (November 18, 2019): 1232. http://dx.doi.org/10.3390/met9111232.

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This paper presents results of the research focused on the possibility of the restoration of the shape parts of molds made of X15CrNiSi20-12 (EN 100 95) heat-resistant austenitic chromium-nickel stainless steel working in high-pressure die casting of aluminum alloys by clad welding. There were tested two welding wires—E Ni 6625 and E 18 8 Mn B 2 2—deposited on X15CrNiSi20-12 (EN 100 95) tool steel using cold metal transfer (CMT) welding in a protective atmosphere of Ar. The resistance of welds was tested against dissolution in molten aluminum alloy ENAC-AlSi9 and the testing procedure was designed. The resistance of welds against dissolution were assessed by exposition of welded clads in an aluminum melt for 120 and 300 min. The EDX semi-quantitative microanalyses of element distribution were performed at the welding–melt interface, and build-ups were also observed on the surface of welded clads.
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Wei, Fufa, Yunming Zhu, Yifeng Tian, Hongning Liu, Yongqiang Zhou, and Zhengqiang Zhu. "Resistance Spot-Welding of Dissimilar Metals, Medium Manganese TRIP Steel and DP590." Metals 12, no. 10 (September 25, 2022): 1596. http://dx.doi.org/10.3390/met12101596.

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Resistance spot-welding of dissimilar metals, medium manganese TRIP steel 7Mn and DP590, is carried out. The effects of single-pulse welding parameters and a double-pulse-tempering current on the quality characteristic parameters and mechanical properties of 7Mn/DP590 spot-welded joints are studied. The welding process parameters are optimized using the control variable method. The results show that the optimal process parameters under a single pulse are as follows: electrode pressure: 4.5 kN, welding current: 9 kA and welding time: 300 ms. The failure mode of the welding joint is partial pull-out failure (PF-TT). The welding parameters have great influence on the nugget diameter and thickness reduction. Expulsion, crack and shrinkage are displayed in the joint under high electrode pressure. Softening occurs in the heat-affected zone due to a strong halo effect in the single-pulse weld. The tempering zone on the DP590 side is 202.49 HV, which is the lowest hardness point, while the hardness of the nugget zone is 450 HV. The addition of the tempering current homogenizes the microstructure with different failure paths and eliminates the stress. The tensile shear force of the joint increases by 17.13 %. The 7Mn Steel/DP590 resistance spot-welding joint is from the fusion line to the center of the nugget, and the microstructure is composed of plane crystal, cellular crystal, dendritic crystal and columnar crystal, in turn. The nugget zone is composed of lath martensite and a small amount of residual austenite. Fine quasi-spherical and lamellar interbedded cementites are formed in the tempering zone of the DP590-side heat-affected zone.
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Fu, Li, Jie Ren, and Zhong Ming Nie. "Influence of CdZnTe/Au Contact on the Wire Bonding Property between the Down-Lead and Au Electrode." Materials Science Forum 620-622 (April 2009): 247–50. http://dx.doi.org/10.4028/www.scientific.net/msf.620-622.247.

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According to the need to make high quality X-ray or γ-ray detectors made by high resistance CdZnTe, the wire bonding technology between the Au contact layer of CdZnTe wafer and the down-lead has been studied in this paper. The influence of welding parameters and surface treatment of CdZnTe wafer on the welding quality between Au contact layer and down-lead have been discussed in detail, such as chemical and mechanical polishing technology of CdZnTe wafer before welding, thickness of the contact layer of CdZnTe wafer, welding energy, welding pressure, welding time, and etc. The results showed that the successful jointing between Au contact layer of CdZnTe and down-lead can be achieved when applying the suitable welding parameters and pretreatment technology of CdZnTe wafer. The optimized welding parameters for CdZnTe wafer were as follows: welding power 2w, welding pressure 60×10-3 kg, welding time 20ms and the power for fire ball formation 1.5w.
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Černý, Ivo, and Jan Kec. "Evaluation of Fatigue Resistance of Laser Welded High Pressure Vessels Steel P355 Considering Fracture Mechanics Approach." Key Engineering Materials 827 (December 2019): 428–33. http://dx.doi.org/10.4028/www.scientific.net/kem.827.428.

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Laser welding is an innovative technology of joining metallic materials. In comparison with conventional arc welding, it has numerous advantages, like high energy of laser beam and high effectiveness, very good reproducibility, possibilities of automation, low energy consumption etc. High pressure vessels and high pressure pipeline industry represent perspective new fields of application. However, since pressure vessels and pipelines are usually operated at conditions of repeated or cyclic loading, an acceptable resistance to fatigue loading of the welds has to be demonstrated. In this contribution, results of an experimental programme aimed at an evaluation of high-cycle fatigue resistance in and near laser welds of a P355 pressure vessel steel are presented and discussed. Particular attention is paid to evaluation of crack initiation mechanisms in connection to laser weld character and welding imperfections. The programme is completed by measurement of fatigue crack growth rates and threshold values in the weld. Results of high-cycle fatigue tests of some groups of specimens were characteristic by a considerable scatter. The reason of the scatter was found in welding defects in some parts of the welds. Fatigue results are discussed also from the viewpoint of fracture mechanics and threshold values of fatigue crack growth.
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Alzahougi, A., M. Elitas, and B. Demir. "RSW Junctions of Advanced Automotive Sheet Steel by Using Different Electrode Pressures." Engineering, Technology & Applied Science Research 8, no. 5 (October 13, 2018): 3492–95. http://dx.doi.org/10.48084/etasr.2342.

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Based on this study, the effects of the different types of welding currents and electrode pressures on the tensile shear properties of the resistance spot welding (RSW) which are the joints of the commercial DP600 sheet steel are now been investigated. In addition to the fact that the electrode pressure is not much of a popular piece or topic of discussion in the literature, the expression of the mechanical properties of these commercial materials (most importantly in the DP and in the high strength steels). These factors that are known to be affecting the strength of the material are dispute. In the tensile shear tests of this welded joints; the tensile shear force and the maximum displacement were utilized to characterize the performance of the welding processes. The nugget diameter has been measured to create a clear definition of the RSW physical properties. The experimental results show that the tensile shear load bearing capacity is bond to increase as the electrode pressure increases based on a value in both the welding currents and the decrease at the higher values. The low current value at low and at the highest electrode pressures; during the high current value which could be at the middle of the electrode pressure values it can exhibit the superior mechanical properties. The effect of this electrode pressure on the tensile shear load bearing capacity is bond to increase as the welding current increases as well. This, also been assessed and examined based on the low carbon content.
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Li, Xing Rui, Wen Bo Tang, and Ji Tai Niu. "Investigation on Joining Mechanism of SiC Particle Reinforced Aluminum Matrix Composite (Al/SiCp-MMC) by Resistance Spot Welding." Materials Science Forum 704-705 (December 2011): 1399–405. http://dx.doi.org/10.4028/www.scientific.net/msf.704-705.1399.

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The present study had investigated the joining performance of SiC particle reinforced aluminum metal matrix composite (Al/SiCp-MMC) having 1.0mm thickness by resistance spot welding processes. The welded joints were subjected to tensile-shearing tests in order to determine the strength of the welded zone. In addition both scanning electron microscopy (SEM) and optical microscopy (OM) were conducted to investigate the micro structural and micro hardness’s changes of the welded joints. The results reveal that: the maximum tensile-shear strength value of welded joint was obtained in these optimum welding parameters as in 17.5kA welding current for 60 periods welding. The electrode pressure was 3.5kN. It was favorable to select relatively high welding current and short welding time for improving mechanical properties of spot welded SiCp/LY12 composite joint. In this base, the welding mechanism of resistance spot welding SiCp/LY12 composite has also been discussed in detail.
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Wei, Yanni, Hui Li, Fu Sun, and Juntao Zou. "The Interfacial Characterization and Performance of Cu/Al-Conductive Heads Processed by Explosion Welding, Cold Pressure Welding, and Solid-Liquid Casting." Metals 9, no. 2 (February 16, 2019): 237. http://dx.doi.org/10.3390/met9020237.

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The Cu/Al composites conductive head is widely used in hydrometallurgy as the core component of cathode plate. Its conductive properties directly affect the power consumption, and the bonding strength and corrosion resistance determine the conductive head service life. The Cu/Al conductive head prepared by explosion welding, cold pressure welding, and solid-liquid casting methods were investigated in this paper. The interface microstructure and compositions were examined by scanning electron microscope and X-ray energy dispersive spectrometry. The bonding strength, interface conductivity, and the corrosion resistance of three types of joints were characterized. The Cu/Al bonding interface produced by explosive welding presented a wavy-like morphology with typical defects and many of brittle compounds. A micro-interlocking effect was caused by the sawtooth structures on the cold pressure welding interface, and there was no typical metallurgical reaction on the interface. The Cu/Al bonding interface prepared by solid-liquid casting consisted mainly of an Al-Cu eutectic microstructure (Al2Cu+Al) and partial white slag inclusion. The thickness of the interface transition layer was about 200–250 µm, with defects such as holes, cracks, and unwelded areas. The conductivity, interfacial bonding strength, and corrosion resistance of the conductive head prepared by explosive welding were superior to the other two.
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Mabrouki, Mohamed, Diogo Gonçalves, Serge Pascal, Denis Bertheau, Gilbert Henaff, and Angéline Poulon-Quintin. "Optimization of the Pressure Resistance Welding Process for Nuclear Fuel Cladding Coupling Experimental and Numerical Approaches." Metals 13, no. 2 (January 31, 2023): 291. http://dx.doi.org/10.3390/met13020291.

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An approach coupling experimental tests and numerical simulation of the pressure resistance welding (PRW) process is proposed for optimizing fuel cladding welds for the new generation of nuclear reactors. Several experimental welds were prepared by varying the dissipated energy, which accounts for the effect of electric current and welding time applied during the PRW process. A working zone, a function of both applied dissipated weld energy and plug-displacement, was then identified on the basis of the microscopy observations of the weld defects. In addition, the numerical approach, based on a 2D axisymmetric multi-physics finite element model, was developed to simulate the PRW process in a plug-tube configuration. The proposed model accounted for interactions between the electrical, thermal and mechanical phenomena and the electro-thermo-mechanical contact between the pieces and electrodes. Numerical simulations were first validated by comparison to experimental measurements, notably by comparing the plug-displacement and the size and position of the heat-affected zone (HAZ). They were then used to assess the effect of the applied parameters on the maximum temperature and cumulated plastic strain reached during welding and the effect of the welding force on the quality of the weld. According to the numerical computations, the maximum temperature reached in the weld remains well below the melting temperature. Changing the welding force implies also modifying the applied energy in order to maintain the quality of the welds. Applied to different plug and clad geometries, the proposed model was shown to be useful for optimizing the joint plane for such a welding configuration.
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Muhammad, Norasiah, Yupiter H. P. Manurung, Roseleena Jaafar, Sunhaji Kiyai Abas, Abdul Ghalib Tham, M. Ridzwan A. Rahim, and Amar Mansor. "Modeling and Optimization of Weld Zone Development in Resistance Seam Welding." Advanced Materials Research 576 (October 2012): 173–76. http://dx.doi.org/10.4028/www.scientific.net/amr.576.173.

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Resistance Seam Welding (RSEW) is an ideal welding method to produce airtight joints where welding input parameters play a very significant role in determining the quality of weld nugget and heat affected zone (HAZ) formation. This research is aimed to study the nugget and HAZ development of 1 mm low carbon steel using RSEW. Welding parameters such as weld current, weld time, weld speed and pressure were identified and investigated to study their effect on the formation of weld nugget by using 24 factorial designs. The objective of this work is to find the optimum parameter to optimize the width of weld nugget and HAZ in order to obtain a good quality of RSEW. Furthermore the mathematical models were developed to predict the weld zone development. Experimental confirmation test was conducted at an optimal condition for observing accuracy of the developed model. Based on the confirmation test, the proposed method can be effectively used to predict the size of weld zone which can improve the welding quality and performance in RSEW.
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Sifa, Agus, Mohamad Adib Ichwan, and Tito Endramawan. "PENGARUH ARUS DAN WAKTU PADA MICRO RESISTANCE SPOT WELDING TERHADAP BAJA AISI 304 DAN ALUMINIUM PADUAN." Jurnal Rekayasa Mesin 14, no. 1 (May 29, 2023): 115–25. http://dx.doi.org/10.21776/jrm.v14i1.1100.

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Welding is often used in industry as a joining technique, one of which is Micro Resistance Spot Welding (MRSW). MRSW was carried out to know the maximum load and shear stress produced on separate worksheets using AISI 304 and aluminum alloys and then connected using a lap joint. This study uses weld current, weld time, and emphasis on the electrodes. In this, welding is done constantly and does not use cooling. The currents used in welding are 140, 280, and 420 A, then varied with the welding time of 24 ms, 34 ms, and 44 ms and combined with a pressure of 1.3 bar. After welding, the welding results are tested using tensile tests and weldability tests. The results of the study were taken with the highest maximum load on a differentiated worksheet. The highest maximum load is generated at the connection of AISI 304 with AISI 304. In contrast to the connection using aluminum alloys, the resulting load will decrease.
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Schwenck, Adrian, Tobias Grözinger, Thomas Günther, Axel Schumacher, Dietmar Schuhmacher, Kai Werum, and André Zimmermann. "Characterization of a PCB Based Pressure Sensor and Its Joining Methods for the Metal Membrane." Sensors 21, no. 16 (August 18, 2021): 5557. http://dx.doi.org/10.3390/s21165557.

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Essential quality features of pressure sensors are, among other accuracy-related factors, measurement range, operating temperature, and long-term stability. In this work, these features are optimized for a capacitive pressure sensor with a measurement range of 10 bars. The sensor consists of a metal membrane, which is connected to a PCB and a digital capacitive readout. To optimize the performance, different methods for the joining process are studied. Transient liquid phase bonding (TLP bonding), reactive joining, silver sintering, and electric resistance welding are compared by measurements of the characteristic curves and long-term measurements at maximum pressure. A scanning electron microscope (SEM) with energy-dispersive X-ray spectroscopy (EDX) analysis was used to examine the quality of the joints. The evaluation of the characteristic curves shows the smallest measurement errors for TLP bonding and sintering. For welding and sintering, no statistically significant long-term drift was measured. In terms of equipment costs, reactive joining and sintering are most favorable. With low material costs and short process times, electric resistance welding offers ideal conditions for mass production.
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Ramadan, Ibrahim, and Maria Tanase. "Experimental Study Regarding the Influence of Welding Parameters on the Mechanical Behaviorof High Density Polyethylene Pipes." Materiale Plastice 57, no. 4 (January 6, 2021): 209–15. http://dx.doi.org/10.37358/mp.20.4.5420.

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The experimental study conducted for this article was made using the butt fusion welding procedure for high density polyethylene (HDPE) pipes. PE100 (SDR 17, PN 10) water pipes were used, as for the experimental study parts of around 200 to 300 mm were welded, using different welding parameters. The influence of the welding parameters on the pipes resistance was analyzed, through visual examination and experimental tests such as tensile, bending and pressure tests.
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Zhao, Dawei, Nikita Vdonin, Mikhail Slobodyan, Sergei Butsykin, Alexey Kiselev, and Anton Gordynets. "Assessing Electrode Characteristics in Continuous Resistance Spot Welding of BH 340 Steel Based on Dynamic Resistance." Journal of Manufacturing and Materials Processing 7, no. 6 (December 4, 2023): 218. http://dx.doi.org/10.3390/jmmp7060218.

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The aim of this investigation is to offer a data-based scheme for predicting electrode wear in resistance spot welding. One of the major factors affecting the mechanical properties of spot welds and the variation in weld quality is electrode wear and alloying. In this study, Rogowski coils and twisted pairs attached to the top and bottom electrodes were used to obtain the welding current and the voltage between the electrodes in the welding process, thereby calculating the dynamic resistance value during the welding process. The electrode tip diameter was obtained from the pressure exerted by the upper and lower electrodes on the carbon paper when the current was cut off and was regarded as an indicator of electrode wear. By continuously welding 0.5 mm thick BH 340 steel plates until the electrode failed, the dynamic resistance signal was recorded in real time. Simultaneously, the electrode diameter after every several welds was also recorded. On this basis, the correlation between electrode tip diameter and dynamic resistance is studied. In order to quantitatively study the mapping relationship between dynamic resistance and electrode wear, 10 characteristic values were extracted from the dynamic resistance, and the stepwise regression method was used to obtain the regression formula between the characteristic values and the electrode tip diameter. Using new data to verify the effectiveness of the regression model, the acquired results display that the maximum error between the predicted value of the electrode tip diameter and the measured value obtained by the regression equation with the interactive quadratic term is 0.3 mm, and the corresponding relative error is 7.69%. When welding with a new pair of electrodes, the maximum absolute error was 0.72 mm, and the relative error of the model prediction is within 20% according to the linear regression model with interaction terms. This indicates that this regression model is barely satisfactory for monitoring electrode condition.
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Georgescu, B., and G. Simion. "A Synthetic Approach to Cold Pressure Welding on Cogged Surfaces." Annals of Dunarea de Jos University of Galati. Fascicle XII, Welding Equipment and Technology 34 (December 30, 2023): 57–64. http://dx.doi.org/10.35219/awet.2023.06.

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Abstract:
Pressure welding on cogged surfaces represents a new technological variant of the cold welding. The components that are made from a material with higher plasticity (aluminium, lead etc.), having flat surfaces, are pressed on or between the harder material components (copper, brass, carbon/stainless steel, titanium, etc.) that have cogged surfaces. The main particularity of this technique is to achieve an appropriate joint by deforming only the component with higher plasticity. Due to the low degree of deformation needed, reduced pressure forces are applied in comparison with the classical cold pressure welding. The welding in isolated catching nodes is achieved by gripping, while the aluminium is gliding on the flanks of the teeth. The tensile strength of the joint is relatively low reaching up to 10% of the aluminium part, but can be improved by applying a heat treatment. Welded joints were made in various combinations, resulting in bimetallic or multilayered workpieces. Due to the negligible contact resistance, these joints can be appropriately used for applications in the electrotechnical field.

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