Quality control based on electrode displacement and force in resistance spot welding

doi:10.1007/s11465-010-0114-x

Front Mech Eng Chin

2010, Vol. 5

Issue (4) : 412-417 https://doi.org/10.1007/s11465-010-0114-x

RESEARCH ARTICLE

Quality control based on electrode displacement and force in resistance spot welding

Chuntao JI(

), Lipeng DENG

School of Material Science and Engineering, Nanchang Hangkong University, Nanchang 330034, China

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Abstract

The behaviors of electrode displacement and force during spot welding under various conditions, such as different weld currents, electrode forces, and welding times, were studied. Tests were conducted on a 170?kVA MFDC spot welder. Data were collected via a multichannel high-speed data acquisition system and were analyzed with MATLAB. Behaviors of 5182 aluminum and mild steel in spot welding were compared. Results show that nugget expansion rate does not reach zero for aluminium as it does for mild steel as nugget grew to a certain size. A linear relationship is found between the nugget size and maximum expansion that facilitates online weld quality evaluation. An electrode force peak is observed and believed relevant to the sufficient nugget size.

Keywords aluminum electrode displacement electrode force nugget size data acquisition

Corresponding Author(s): JI Chuntao,Email:chuntaoji@hotmail.com

Issue Date: 05 December 2010

Cite this article:

Chuntao JI,Lipeng DENG. Quality control based on electrode displacement and force in resistance spot welding[J]. Front Mech Eng Chin, 2010, 5(4): 412-417.

URL:

https://academic.hep.com.cn/fme/EN/10.1007/s11465-010-0114-x
https://academic.hep.com.cn/fme/EN/Y2010/V5/I4/412

Fig.1 Data acquisition system

Fig.2 Electrode displacement under different force. (a) Material: 1.5 mm×1.5 mm aluminum, and weld current: 20 kA; (b) material: 1 mm×1mm mild steel, and weld current: 7kA

Fig.3 Electrode displacement at different weld current. (a) Material: 1.5 mm×1.5 mm aluminum, and force: 1300 lb; (b) material: 1 mm ×1 mm mild steel, and force: 480 lb.

Fig.4 Relationship between nugget size and maximum displacement. Material: 1.5 mm ×1.5 mm aluminum, force: 1300 lb

Fig.5 Electrode force at different weld current. Material: 1.5 mm×1.5 mm aluminum. Force: 1300 lb

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