An Experimental Study and Simulation of Resistance Spot Welding With Rectangular Electrode

AN EXPERIMENTAL STUDY AND SIMULATION OF
RESISTANCE SPOT WELDING WITH

RECTANGULAR ELECTRODE

A dissertation submitted in partial fulfillment of the requirements for the award of the degree

of

MASTERS OF ENGINEERING (CAD/CAM)

BY

MOHAMMED ABDUL SAMAD
1604-10-765-003

DEPARTMENT OF MECHANICAL ENGINEERING
MUFFAKHAM JAH COLLEGE OF ENGINEERING AND TECHNOLOGY
(Affiliated to Osmania University)
HYDERABAD-500034
2013

AN EXPERIMENTAL STUDY AND SIMULATION OF
RESISTANCE SPOT WELDING WITH
RECTANGULAR ELECTRODE

A Dissertation submitted in partial fulfillment of the requirements
For the award of the Degree of

MASTER OF ENGINEERING

with specialization in

CAD/CAM

By

MOHAMMED ABDUL SAMAD
1604-10-765-003

Under the guidance of
Mr. SHAIK SHAFEE M.Tech (Ph.D.)
Senior Assistant Professor

DEPARTMENT OF MECHANICAL ENGINEERING
MUFFAKHAM JAH COLLEGE OF ENGINEERING AND TECHNOLOGY
(AFFILIATED TO OSMANIA UNIVERSITY)
BANJARA HILLS, HYDERABAD-500 034

2013

ACKNOWLEDGMENTS

I extend my humble and most sincere thanks to my guide Mr. SHAIK
SHAFEE for his unmatchable enthusiasm, constant motivation, and privileged
guidance, which led me throughout the last year to complete the work undertaken.
I would also like to thank Dr. N. SEETHARAMIAH (Coordinator, M.E
(CAD/CAM)), for their constant zeal and guidance for the completion of the project
on time.
I would also like to thank Dr. KHADAR VALI (Head, MED) and all the
teaching and non-teaching staff of the MJCET who have helped and cooperated with
me during completion of this work, in whatever possible way they could have helped.
I would also like to thank Principal & Advisor-cum-Director,
MuffakhamJah College of Engineering and Technology and all the teaching and non-
teaching staff of the MJCET who have helped and cooperated with me during
completion of this work, in whatever possible way they could have helped.
I thank Mr. Abdul Waheed, Junior Assistant, MJCET, for his help
throughout the main course and dissertation programme.
I would like to convey my gratitude to all my friends and all staff members of
Mechanical Engineering Department for their support and encouragement.
The meaning of my life and work is incomplete without paying regards to my
respected parents whose blessings and continuous encouragement have shown me the
path to achieve my goals. I feel pleased and privileged to fulfill my parents ambition
and I am greatly indebted to them for bearing the inconvenience during my M-E
course.

MOHAMMED ABDUL
SAMAD
(1604-10-765-003)

ii

DECLARATION

I hereby declare that the work presented in this dissertation entitled as AN
EXPERIMENTAL STUDY AND SIMULATION OF RESISTANCE SPOT WELDING WITH
RECTANGULAR ELECTRODE, submitted in partial fulfillment of the requirement for
the award of the Degree of Master of Engineering with specialization in
CAD/CAM, in the Department of Mechanical Engineering, MuffakhamJah College
of Engineering and Technology, Hyderabad is an authentic record of my own work
carried out from august 2011 to July 2013 under the guidance and supervision of Mr.
SHAIK SHAFEE, Assistant Professor Department of Mechanical Engineering,
MJCET.
I have not submitted the matter embodied in this report for the award of any
other degree or diploma.

MOHAMMED ABDUL
SAMAD
(1604-10-765-003)

iii

A B S T R A C T

Resistance spot welding is a widely used joining process for fabricating sheet metal
assemblies such as automobiles, truck cabins and rail vehicles due to its advantages
and suitability for automation. This Project work seeks to characterize the nugget
formation patterns of spot welding of stainless steel sheets under different welding
conditions with rectangular electrode by both numerical simulation and experiments.
The objective of this project work is to develop a numerical model of the resistance
spot welding process with rectangular electrode, enabling to predict accurately the
weld geometry development. A 2D axisymmetric electro-thermo-mechanical finite
element (FE) model is developed to study the effect of spot welding parameters on
nugget size using ANSYS commercial software package. Both the simulations and
experiments were carried out on the two different thicknesses of stainless steel sheets
under the varying welding conditions. The nugget diameters obtained from numerical
simulations are compared with the experimental results. The FE predicted weld
nugget size agrees well with the experimental results. Temperature field of resistance
spot welding with rectangular electrode was obtained from numerical simulation.
Shear tensile strength of the spot welded joint was also investigated. Experiments
were carried out to verify the preciseness of simulation.Overall, the present work
indicated that finite element analysis can be very useful as an off-line observation tool
to estimate the influence of welding parameters on the welding quality with
rectangular electrode and to predict or improve the welding quality.

iv

TABLE OF CONTENT

Title page

Certificate

Acknowledgements ii
Declaration iii
Abstract iv

CHAPTER 1: INTRODUCTION 1

1.0 PRINCIPLE OF RESISTANCE SPOT WELDING 2
1.1 RESISTANCE SPOT WELDING (RSW) FOR STAINLESS STEEL
5
1.1a: AISI 304 Grade Austenitic Stainless Steel 6
1.1b: Corrosion Resistance of AISI 304 7
1.2 OBJECTIVES 8

CHAPTER 2: LITERATURE REVIEW 9
2.1 OVERVIEW 9

2.2 THORETICAL BACKGROUND 10
2.3 RECENT WORK 20
2.4 SUMMARY 26

CHAPTER 3: SPOT WELDING FACTORS 27
3.1 SPOT WELDING MACHINE 27
3.1.1 ELECTRICAL SYSTEM 27
3.1.2 MECHANICAL SYSTEM 27
3.1.3 AIR OPERATED MACHINES 28
3.1.4 CONTROL SYSTEM 29
3.1.5 COOING SYSTEM 29
3.1.6 A.C RESISTANCE WELDING MACHINE 30
3.1.7 A.C SPECIFICATION OF RESITANCE WELDING MACHINE
30
3.2 SPOT WELD NUGGET DIAMETER 33
3.3 SPOT WELD NUGGET DIMENSION CHECKING 35

CHAPTER 4: EXPERIMENTAL STUDY 37
4.1 EXPERIMENTAL PREPARATIONS 37
4.2 PEEL TEST 52
4.3 SHEAR TENSILE TEST 53

CHAPTER5: INTRODUCTION TO SIMULATION OF RSW
PROCESS 63

5.1 SIZE OF ELECTRODES 65
5.2 COMPUTATIONAL MODEL 65
5.3 GOVERNING EQUATION67
5.4 HEAT TRANSFER ANALYSIS 68
5.5 BOUNDARY CONDITIONS 71
5.5.1 MECHANICAL BOUNDARY CONDITIONS 71
5.6 MATERIAL PROPERTIES 71

5.7 SOLVING PROCEDURE 73
5.8 WELDING PARAMETERS AND CONTACT RESISTANCE 78
5.9 SIMULATION OF STAINLESS STEEL SHEETS OF
0.8mm & 1.0mm THICKNES 80

CHAPTER 6: CONCLUSIONS AND FUTURE SCOPE OF WORK 93

6.1 CONCLUDING REMARKS 93
6.2 FUTURE SCOPE OF WORK 94

REFERENCES 95

LIST OF TABLES

Table 1.1: Chemical Compositions of 304 Grade Stainless Steel 7
Table 1.2: Mechanical Properties of 304 Grade Stainless Steel 7

Table 4.0: Specifications of the Spot Welding Machine 38

Table 4.1: Spot Welding process Parameters and their values for 0.8mm
and 1.0mm thickness of sheet metal with constant welding Time 43

Table 4.2: Experimentally measured values of Nugget Diameter of 0.8mm and 1mm
thickness of sheet metal with constant welding time (75cycles) 45

Table 4.3:Spot Welding process Parameters and their values for
0.8mm and 1.0mm thickness of sheet metal with constant welding 45

Table 4.4: Experimentally measured values of Nugget Diameter of 0.8mm
and 1.0mm thickness of sheet metal with constant welding time (100cycles) 47

Table 4.5: Spot Welding process Parameters and their values for 0.8mm and 1.0mm
thickness of sheet metal with constant welding Time 47

Table 4.6: Experimentally measured values of Nugget Diameter of 0.8mm and
1mm thickness of sheet metal with constant welding time (125cycles) 49

Table 4.7: Spot Welding process Parameters and their values for 0.8mm and 1.0mm
thickness of sheet metal with constant welding Time 49

Table 4.8: Experimentally measured values of Nugget Diameter of 0.8mm and 1mm
thickness of sheet metal with constant welding time (150cycles) 51

Table 4.9: Experimentally obtained values of Nugget diameter and Shear
Tensile Test (75 Cycles) 61




Table 5.1: Welding parameters for the simulation 67

Table 5.2: Boundary conditions 68

Table 5.4: Thermal and electrical properties of of the employed SS304 and
copper electrodes 75

Table 5.5: Physical and mechanical properties of the employed SS304 and copper
Electrodes 76

Table 5.6: Element types and degree of freedom options 77

Table 5.7: Employed spot welding Parameters for simulation of 0.8 mm and 1.0mm
thickness sheet metal with constant welding Time 80

Table 5.8: Measured values of Nugget diameter by Simulation of sheets of 0.8 mm
and 1.0mm thickness (75 Cycles) 83





Table 5.13: Employed spot welding Parameters for simulation of 0.8mm and 1.0mm

and 1.0mm thickness (150Cycles) 92

LIST OF FIGURES

Figure 1.1: Principle of Resistance spot welding 4
Figure 1.2: Resistance spot welding with flat electrode 4
Figure 1.3: Micro Structure of Stainless Steel 304L 6

Figure 2.1: Spot welding process details 10
Figure 2.2: Welding Current 11
Figure 2.3: Contact Resistance 13
Figure 2.4: Measured Process Parameters 15
Figure 2.5: Spot Weld Cycle 16
Figure 2.6: Basic resistance Spot Welding Cycles show the relationship of time,
current, and electrode force for each segment 17
Figure 2.7: Depression in the sheet 18
Figure 2.8.a: Influence of Weld Current on Nugget Diameter 19
Figure 2.8.b: Current Measurement 20
Figure 2.9:Temperature Distribution 21
Figure 2.10.a: Relationship of current and time on weld quality 22
Figure 2.10.b: Relation between current and pressure for weld quality 23
Figure 2.11 :Dynamic Resistance 24
Figure 3.1: Overview of mechanical system of spot and projection welding machine
28
Figure 3.2: Various parts of RSW machine 31
Figure 3.3: Resistance spot welding machine 32

Figure 3.4: Schematic view of nugget size diameter 35
Figure 3.5: Different zones of weld nugget 36

Figure 4.1: Experimental setup for RSW 38
Figure.4.2: Flat Rectangular bottom Electrode 39
Figure.4.3: Flat Rectangular bottom Electrode 39
Figure.4.4: Assembled flat Rectangular bottom Electrode 40
Figure.4.5: Spot weld being carried out on Rectangular bottom Electrode 41
Figure.4.6: Spot weld being carried out on Rectangular bottom Electrode 42
Figure.4.7: Sample coupons of 0.8 mm & 1.0 mm thickness of SS 304 for
spot welding 43
Figure.4.8: Sample coupons of 0.8 mm & 1mm thickness of sheet metal
before spot welding (75 cycles) 44
Figure.4.9: Sample coupons of 0.8 mm & 1.0 mm thickness of sheet metal
after spot welding (75 cycles) 44
before spot welding (100cycles) 46
after spot welding (100cyles) 46
Figure.4.12:Sample coupons of 0.8 mm & 1mm thickness of sheet metal
after spot welding (125 cyles) 48

Figure.4.15: Sample coupons of 0.8 mm & 1mm thickness of sheet meta
l after spot welding (150 cyles) 50

Figure.4.16: SPOT WELDED SAMPLE FOR PEEL TEST 51
Figure.4.17: Peel Test being carried out for measuring the Nugget Diameter 52
Figure.4.18: Peel Test being carried out for measuring the Nugget Diameter 52
Figure.4.19: Spot Welded Work Pieces after Peel Test 53
Figure.4.20: The tensileshear strength test 54
Figure.4.20a: Spot welded sample for shear tensile test 54
Figure.4.20b: Spot welded sample for shear tensile test 55
Figure.4.20c: Spot welded sample for shear tensile test 55

Figure.4.20d: Spot welded sample for shear tensile test 56
Figure.4.21: Shear Tensile Test being Carried out 56
Figure.4.22: Shear Tensile Test being Carried out 57
Figure.4.24a :The tensileshear strength test (1) separation 58
Figure.4.24 b :The tensileshear strength test (2) shearing 59
Figure.4.24 c :The tensileshear strength test (3) tearing 60

Figure.5.1: The size of electrodes 66
Figure. 5.2: Schematic of the (a) electro-thermal boundary conditions, and
(b) mechanical boundary conditions 70
Figure.5.3: Boundary conditions 71
Figure. 5.4: The finite element solving algorithm used for
simulating the RSW process 73

Figure 5-5: The model of spot welding with rectangular electrode 77
Figure 5-6 : 2D Axisymmetric Quarter meshed model geometry 79
Figure 5.7: The predicted temperature distribution from the simulation for the
Sample1 81
Figure 5.8: The predicted temperature ( ) distribution graph with
respect to time in seconds (1cycle = 0.02 seconds) from the simulation for the sample
1 81
Figure 5.9: The predicted temperature ( ) from the simulation for the sample 2
82
2 82
84

3 84
85
4 85
87
5 87
88
6 88
90
respect to time in seconds(1cycle = 0.02 seconds) from the simulation for the sample
7 90
91
Figure 5.22: The predicted temperature ( ) distribution graph with respect
to time in seconds (1cycle = 0.02 seconds) from the simulation for the sample 8

CHAPTER 1

1. INTRODUCTION

Resistance spot welding is a widely used joining process for fabricating sheet metal
assemblies such as automobiles, truck cabins and rail vehicles due to its advantages in
welding efficiency and suitability for automation. The shape of electrode is an
important parameter, and the conventional electrodes can be divided into the taper and
spheriform ones, both of which produce a round welding spot. The weld spacing used
in production must exceed a certain value to avoid shunt current, which lowers nugget
size or even results in incomplete penetration because of decreased current density
and underheating in weld field. The gas tightness of resistance spot welding
construction with conventional electrodes is low; therefore, the conventional
electrodes are suitable for the production with low requirement of gas tightness, but
these are not suitable for production which has high requirement of strength and gas
tightness. The conventional seamwelding cannot satisfy the need of joint in small
scale because of the restrictions of the configuration. In this project work, the
electrode shape was changed into rectangle in order to improve the gas tightness and
extend the application field of resistance spot welding.

On the promise of that the nugget size, strength and surface quality of welding joint
satisfy the requirement, use the maximal length-width ratio of rectangle to increase

the effective joint length and effective area between workpieces and the strength of
heat affected zone was also ensured. The change of electrode shape induces some new
characteristics about nugget formation during resistance spot welding, which should
be investigated. The nugget formation of resistance spot welding with rectangular
electrodes was simulated by ANSYS because of its instantaneity and complexity.
Experiments were carried out to verify the preciseness of simulation and find out the
optimum technological parameters.

Purpose: Over the last few years, there has been a growing interest in quantitative
representation of heat transfer and fluid flow phenomena in weld pools in order to
study relationships between the processing variables and the quality of the weldment
produced and to use this information for the optimization and mobilization of the
welding process.

Design/methodology/approach: A 2D axisymmetric Finite Element Method (FEM)
model has been developed to analyze the transient thermal behaviours of Resistance
Spot Welding (RSW) process. In this model, the temperature dependent material
properties, phase change and convectional boundary conditions were taken in account
for the improvement of the calculated accuracy, but the determination of the contact
resistance at the surface is moderately simplified in order to reduce the calculating
time through the analysis.

Findings: The developed model has been employed the thermal history of the whole
process (including cooling)and temperature distributions for any position in the
weldment.

Research limitations/implications: Future research in the field of RSW processing
could focus on analysis of the stress and strain distributions as well as deformation in
the weldment.

Originality/value: It can be concluded that the maximum temperature was up to
1430C, nearly the molten point of stainless steel, and verified by the observation of
the surface of the weldment after welding.

PRINCIPLE:
The complexity of the resistance spot welding process is represented by various
parameters needed to describe the undergoing physical influences (e.g: electric
current, electrical resistance, contact force, material type, temperature, etc.). By
identifying the temperature field it becomes possible to simulate heating, deformation
and cooling pro cesses, and to ensure some basic assumptions for predicting structural
changes at locations of the joint and its final mechanical properties.

Efforts for developing modern simulations of concern here have four orientations:
Implementing influences of latent heat and phase transformations in the numerical
analysis development of mathematical formulations of thermo-mechanical processes
in resistance spotwelding and their correlation to heat and electrical processes.
Quantification of the contact surface regardless of whether this surface is an
electrode--to-sheet metal or sheet-to-sheet micro contact, as well as changes in
geometry of the conductive media and implementing all particularities of the
resistance spot welding of new materials and alloys into well-established
mathematical models.

The spot welding working principle, as described by Okumura & Taniguchi in their
book is represented here the two metal sheets to be welded are kept in contact through
two copper electrodes, while a very intense electric current passes through this
electric circuit for a short period of time.

The passage of this intense electric current through the circuit releases heat in the
contact interface between the two metal sheets that are being welded by means of
electric resistance. The surfaces are then melted and the pressure kept between the
sheets is enough to create the spot weld. The heat release also happens between the

metal sheets and the electrodes, but these are internally cooled down in a way to avoid
its fusion or the fusion of the sheet metal surface in contact with it.

Although which sketch shows the application of the spot welding bonding two metal
sheets, the same principle can be applied to bond three or even four metal sheets in
some rare cases, but special care should be taken in this case for the thicknesses
involved and the electric current needed, since these designs are more susceptible to
gap induced pre-stresses and lack of weld penetration, as we will discuss further in
this paper. As previously mentioned, one of the biggest advantages of the spot
welding process is the possibility of assembly automation and flexibility through the
usage of different programming for different vehicles in the same assembly line.

Figure 1.1: Principle of Resistance spot welding

Figure 1.2: Resistance spot welding with flat electrode

1.1 RESISTANCE SPOT WELDING FOR STAINLESS STEEL

The chrome-nickel steel alloys (austenitic) have very high electrical resistance and are
readily joined by resistance spot welding. The consideration of great importance with
these materials is rapid cooling through the critical range; 426C to 760C. The rapid
quench associated with resistance spot welding is ideal for reducing the possibility of
chromium carbide precipitation at the grain boundaries. But it is important to note that
the longer the weldment is held at the critical temperatures, the greater is the
possibility of carbide precipitation.

Austenitic stainless steels are used for a very broad range of applications especially in
automotive, railroad, and airplane structures when an excellent combination of
strength and corrosion resistance in aqueous solutions at ambient temperature is
required. These structures are generally in stiffened thin plate constructions where the
thinner plates are reinforced by thicker plates called frame. They have been claimed

as being a cost-effective way of achieving a high performance vehicle structure.
Resistance spot welding (RSW) takes an important role for joining these structures.
The advantages of using RSW are that it is a quicker joining technique, no filler
material is required, and that the low heat input implies less risk for altered
dimensions during welding. However, the spot welded joints have a geometrical
problem on the stiffened thin plate structures due to the thickness difference of joined
materials.

304L stainless steel, which is in the austenitic group, is an extra low carbon stabilized
stainless steel. It is among the stainless steel group, most widely used in deep drawing
and similar shaping processes, and has a good weldability. It has a good resistance
against intergranular and stress corrosion crack and excellent resistance against
atmospheric corrosion. On the other hand, AISI304L is used in applications, where
corrosion resistance is important.

Figure 1.3: Micro Structure of Stainless Steel 304L

1.1a: AISI 304 Grade Austenitic Stainless Steel

Stainless steel types 1.4301 and 1.4307 are also known as grades 304 and 304L
respectively. Type 304 is the most versatile and widely used stainless steel. It is still
sometimes referred to by its old name 18/8 which is derived from the nominal
composition of type 304 being 18% chromium and 8% nickel. Type 304 stainless
steel is an austenitic grade that can be severely deep drawn.

It is the most widely used austenitic stainless steel. Popularly known as 18/8 stainless
steel, it has excellent corrosion resistance and forming characteristics. Used in
chemical, petrochemical and fertilizer industries, and as equipment in diary, food
processing, pharmaceutical industries, in hospitals, households as kitchenware,
cryogenic vessels and as heat exchangers in air conditioning refrigeration, for
machinery in paper, pulp and textile beverage sectors.

1.1b: Corrosion Resistance of AISI 304

It has excellent in a wide range of atmospheric environments and many corrosive
media and subject to pitting and crevice corrosion in warm chloride environments,
and to stress corrosion cracking above about 60C. It is considered resistant to
drinking water with up to about 200mg/L chlorides at ambient temperatures, reducing
to about 150mg/L at 60C [4]. In warm chloride environments, 304 is subject to
pitting and crevice corrosion and to stress corrosion cracking when subjected to
tensile stresses beyond about 50
o
C. However, it can be successful in warm chloride
environments where exposure is intermittent and cleaning is a regular event.

Table 1.1:Chemical Composition of 304 Grade Stainless Steel

Stainless
Steel 304
Carbon Silicon Manganese Phosph
orus
Sulphur Chromium Nickel
Composition
%
0.084 1.00 2.00 0.045 0.03 18/20 8.00

Table 1.2: Mechanical Properties Of 304 Grade Stainless Steel

Grade Tensile
Strength
(Mpa) min
Yield
strength
0.2% proof
(Mpa) min
Elongation
(% in 50mm)
min
Hardness
Rockwell B
(HR B) max
Brinell (HB)
max
304 515 205 40 92 201

1.2 OBJECTIVES

The objectives of the project work are to gain the knowledge within the field of
Resistance spot welding and FEM application in it. The following objectives are
specified:
- To study the spot welding experimentally and by aid of computer simulation.
- To find the effect of variation in parameters in spot welding process.
- To study the effect of application of heat and load to work material.
- To find the effect of variation of current on nugget diameter and shear
strength.
- Also to study the effect of cycle time on nugget diameter and shear strength.
- Find the temperature variations during the process of resistance spot welding.

- To present the work indicated that finite element analysis can be very useful as
an off-line observation tool to estimate the influence of welding parameters on
the welding quality with rectangular electrode and to predict or improve the
welding quality.
- Studying mechanical strength of spot welded joint. (Manufacture of lap shear
joint test for tensile shear testing and nugget size measurement, in order to
compare the performance of different welding parameters with respect to weld
mechanical strength)

CHAPTER 2

LITERATURE REVIEW

Resistance spot welding is a process that has been widely used in sheet metal
fabrication, with advantages of high speed suitability of automation and inclusion
in high production assembly lines with the other fabricating operations. This
chapter deals with the principle and theoretical background of spot welding process.
Also some light is given on the recent work in this area.

2.1 OVERVIEW

Resistance spot welding was invented in 1877 by Eiihu Thomson and has been widely
used since then as manufacturing process in process for joining sheet metal. A
resistance welding machine is designed to pass electrical current through the parts to
be joined, bringing these components to plastic state. Once in this state, a mechanical
force is required to forge the parts together. This process if applied correctly, will
produce a weld nugget that is stronger than the base metal. The correct application of
electrode force will eliminate metal expulsion (flash) and minimize electrode wear.
Even when joining galvanized steel, a clean strong joint can be accomplished without
the usual sparks seen in most resistance welding process. Fused properly, the
resistance welding process is the fastest and most economical process of joining sheet
metals [1]. The basic joint is primarily accomplished through forging of plastic state
material. To reach this ideal state, a proper balance between force and heat must be
obtained. Since heat is created between parts being joined by the voltage drop across
the electrical resistance (nugget area), a higher force will lower this resistance and
thus reduce the effective heat. Reduction of force will raise this resistance to provide
higher heat, but at same time lower the forging action of the machine. The balance
between these two factors is important.

Spot wel di ng process-detai ls
nugget
diameter
Weld
nugget
Electrode
Tip
diameter
Indentation
Sheet
separation
Heat affected
zone
Electrode
tip
Faying
surfaces

Figure 2.1: Spot welding process details

2.2 THEORETICAL BACKGROUND

The principle of resistance welding is the Joule heating law where the heat Q is
generated depending on three basic factors as expressed in the following formula:

Q = I
2
Rt

Where I is the current passing through the metal combination, R is the resistance
of the base metals and the contact interfaces, and t is the duration/time of the current
flow. In an actual welding process, there are numerous parameters; some researchers
had identified more than 100, to influence the results of a resistance welding. In order
to have a systematic understanding of the resistance welding technology, the most
influential parameters are summarized into the following eight types:

1) Welding current:

The welding current is the most important parameter in resistance welding which
determines the heat generation by a power of square as shown in the formula. The size
of the weld nugget increases rapidly with increasing welding current, but too high
current will result in expulsions and electrode deteriorations. The figure below shows
the typical types of the welding current applied in resistance welding including the
single phase alternating current (AC) that is still the most used in production, the three
phase direct current (DC), the condensator discharge (CD), and the newly developed
middle frequency inverter DC. Usually the root mean square (RMS) values of the
welding current are used in the machine parameter settings and the process controls.

Figure 2.2: Welding Current

2) Welding Time:

The heat generation is directly proportional to the welding time. Due to the heat
transfer from the weld zone to the base metals and to the electrodes, as well as the
heat loss from the free surfaces to the surroundings, a minimum welding current as
well as a minimum welding time will be needed to make a weld. If the welding
current is too low, simply increasing the welding time alone will not produce a weld.
When the welding current is high enough, the size of the weld nugget increases with
increasing welding time until it reaches a size similar to the electrode tip contact area.

If the welding time is prolonged, expulsion will occur or in the worst cases the
electrode may stick to the workpiece.

3) Welding Force:

The welding force influences the resistance welding process by its effect on the
contact resistance at the interfaces and on the contact area due to deformation of
materials. The workpieces must be compressed with a certain force at the weld zone
to enable the passage of the current. If the welding force is too low, expulsion may
occur immediately after starting the welding current due to fact that the contact
resistance is too high, resulting in rapid heat generation. If the welding force is high,
the contact area will be large resulting in low current density and low contact
resistance that will reduce heat generation and the size of weld nugget

4) Contact Resistance:

The contact resistance at the weld interface is the most influential parameter related to
materials. It however has highly dynamic interaction with the process parameters. The
figure below shows the measured contact resistance of mild steel at different
temperatures and different pressures. The contact resistance generally decreases with
increasing temperature but has a local ridge around 300C, and it decreases almost
proportionally with increasing pressure. All metals have rough surfaces in micro
scale. When the welding force increases, the contact pressure increases thereby the
real contact area at the interface increases due to deformation of the rough surface
asperities. Therefore the contact resistance at the interface decreases which reduces
the heat generation and the size of weld nugget. On the metal surfaces, there are also
oxides, water vapour, oil, dirt and other contaminants. When the temperature
increases, some of the surface contaminants (mainly water and oil based ones) will be
burned off in the first couple of cycles, and the metals will also be softened at high
temperatures. Thus the contact resistance generally decreaseswith increasing
temperature.

Figure 2.3: Contact Resistance

5) Materials properties:

Nearly all material properties change with temperature which adds to the dynamics of
the resistance welding process. The resistivity of material influences the heat
generation. The thermal conductivity and the heat capacity influence the heat transfer.
In metals such as silver and copper with low resistivity and high thermal conductivity,
little heat is generated even with high welding current and also quickly transferred
away. They are rather difficult to weld with resistance welding. On the other hand,
they can be good materials for electrodes. When dissimilar metals are welded, more
heat will be generated in the metal with higher resistivity. Hardness of material also
influences the contact resistance. Harder metals (with higher yield stress) will result in
higher contact resistance at the same welding force due to the rough surface asperities
being more difficult to deform, resulting in a smaller real contact area. Electrode
materials have also been used to influence the heat balance in resistance welding,
especially for joining light and non-ferrous metals.

6) Surface coatings:

Most surface coatings are applied for protection of corrosion or as a substrate for
further surface treatment. These surface coatings often complicate the welding
process. Special process parameter adjustments have to be made according to
individual types of the surface coatings. Some surface coatings are introduced for
facilitating the welding of difficult material combinations. These surface coatings are
strategically selected to bring the heat balance to the weld interface. Most of the
surface coatings will be squeezed out during welding, some will remain at the weld
interface as a braze metal.

7) Geometry and dimensions:

The geometry and dimensions of the electrodes and work pieces are very important,
since they influence the current density distribution and thus the results of resistance
welding. The geometry of electrodes in spot welding controls the current density and
the resulting size of the weld nugget. Different thicknesses of metal sheets need
different welding currents and other process parameter settings.

8) Welding machine characteristics:

The electrical and mechanical characteristics of the welding machine have a
significant influence on resistance welding processes. The electrical characteristics
include the dynamic reaction time of welding current and the magnetic / inductive
losses due to the size of the welding window and the amount of magnetic materials in
the throat. The up-slope time of a welding machine can be very critical in micro
resistance welding as the total welding time is often extremely short. The magnetic
loss in spot welding is one of the important factors to consider in process controls.
The mechanical characteristics include the speed and acceleration of the electrode
follow-up as well as the stiffness of the loading frame/arms. If the follow-up of the
electrode is too slow, expulsion may easily occur in projection welding.

Figure 2.4: Measured Process Parameters

9) Cooling the Workpiece

Electrodes get considerably hot with 1-10 KA or more welding current repeatedly
flowing under hundreds of newtons of force. Although most welders have an internal
water cooling system that allows water to circulate through the tips of the electrodes
while welds are being made, a common problem is a lost, damaged or improperly
sized cooling water tube. Without anything to cool off the tips, heat can quickly build
up to the point where the electrodes will eventually weld to the workpieces. To
correct this problem, the water tube should be placed so that the incoming cold water
strikes the hottest part of the tip first.

10) Spot Weld Cycle

The spot weld cycle is clearly defined in figure 2.5.Squeeze time, the welding current
is applied at the end of this time. Weld time, the welding current flows through the
circuit. Hold time, the electrode pressure is maintained until the metal has somewhat
cooled. Off time, the interval of the hold time to the beginning of the squeeze
time.Slope Control refers to rise and fall of the welding current as shown in figure
2.6.b. The current may be made to build up gradually (upslope) or to decrease
gradually (down slope or current decay). Upslope gives the electrode a few impulses
of time to seat before they have to carry the full welding current. The down slope or
decay helps to reduce internal cracking of the weld nugget.

Retarding the cooling action ensures a proper temperature during the forging action.
An increase in electrode pressure as the weld solidifies produces the forging effect
(figure 2.6.c). Multiple impulse welding cycles (figure 2.6.d) provide short heating
periods alternating with short cooling periods for better control of the weld nugget,
which reduces spitting. Spitting refers to the molten metal being propelled out from
the weld nugget.
Figure 2.5: Spot Weld Cycle

Stages in making spot weld
Weld Hold Off
Pressure
applied
on Current off Pressure
released
Squeeze
Squeeze
p
r
e
s
s
u
r
e
time
current
Spot welding cycle
Weld Hold

Figure 2.6: Basic resistance Spot Welding Cycles show the relationship of time,
current, and electrode force for each segment

Depression is observed in spot welds when high pressure is applied by the electrode to
the plates as shown in figure. 2.7. The maximum value of depression is 0.10 times
thickness of sheet. The variation w.r.t current is also shown. The graph reveals that
with increasing value of current and time , depression is also increasing.

S1
S2
S1 <S2
depress i max.
i =0,10 S1
depress i max.
i =0,10 S2
Depression of the electrode by spot welding
depress (%)
10 (%)
t3
t2
t1
current (kA)
current time
t1<t2<t3
10 (%)
depression of the electrode
in the surface of the sheet
Figure 2.7: Depression in the sheet

The weld nugget diagram is shown in figure 2.8. Nugget formation is the most
important aspect of resistance spot welding. This is the fusion area between two plates
to be joined.

Figure 2.8.a: Influence of Weld Current on Nugget Diameter

During the process of spot welding very high current flows for extremely short
duration 0.02sec 0.05 sec, ammeter cannot respond so quickly. In spot welding
current is measured with help of toroidal coil. When high current flows it generates
magnetic field and magnetic flux interlink with the coil generate Electromotive force
in proportion to rate of change of current to time V = K di/dt K is constant. Coil
output V is in proportion to the coil area and number of turns. This type of sensor
can measure any large current in differential value. To get absolute value it is interlink
with electronic circuit.

Figure 2.8.b: Current Measurement

2.3 RECENT WORK

According to published literature, research on the spot welding started in early 1950s.
Temperature distribution during the process of spot welding is one of the crucial
aspects for the study. Temperature distribution at various zones during the process is
clear from the following figure 2.9.

Figure 2.9: Temperature Distribution
temp C
welding water
water
water
R1
R2
R3
electrode
Work
pieces

Tsai [2] predicted temperature histories at six locations along the central axis of the
joint (with welding conditions: welding current 1.8kA; weld time 75 cycles; electrode
force 3.6kN). The temperature history at the center of work piece faying surface
shows thermal arrests at liquidus and solidus temperatures of work piece material due
to latent heat effect. He showed that weld nugget initiated at periphery of the contact
area and was in toroid shape. In very short time during the weld cycles, the molten
nugget spread rapidly inward toward the center and very little growth in outward
radial direction. According to Tsai, the nugget grew much faster along the interface
than in material thickness direction and once molten material reached central axis, it
began to grow into the joint thickness as the weld cycles continued.

The attributes for spot weld quality were studied by many researchers. Spindella [3]
suggested that good welds are welds with large buttons and high tensile strength
without expulsion or partial button. In Newton et al [4], a weld with full size nugget
and at least minimum strength, and without cracks, flash or porosity was regarded as
good weld. Their study also tried to define nonconformable weld as those of too small
weld size, or with cracks, excessive porosity, excessive expulsion, and damaged
adhesive layers for weld bonding.

These classifications are generally qualitative and depend on multiple parameters,
inaddition to the materials welded (Steel or Aluminum). In many cases, the nugget
width or button diameter is used as sole parameter to describe the quality of a spot
weld. Current, time and pressure are the three variables which influences weld
quality. The variation of current and pressure; and relation of current and time is
shown in figure 2.10.

Figure 2.10.a: Relationship of current and time on weld quality

Relation between Current and Pressure
Current
P
r
e
s
s
u
r
e
A:High Current and High Pressure
B:Medium current and medium Pressure
C: Small Current and High Pressure
Explosion
Small
Large
Nugget Dia
(Strength)
No Nugget
Splash
G
o
o
d

W
e
l
d
B - will have
Good Weld
Less Spatters
Optimum Nugget Dia
Figure 2.10.b: Relation between current and pressure for weld quality

Zhou [6] attempted to link a welds quality to its attributes under tensile shear testing.
The use of combined statistical design and analyses, and computer simulation
provided a systematic and effective means to study multivariate nature of spot welds.
Through his integrated numerical analysis he found out effect of weld parameters
such as weld diameter, penetration, indentation, size of HAZ and sheet thickness of
base metal on spot weld quality. He also provided J-integral, which was further used
to describe fracture behavior of welded joint by treating edge of weld as crack.

Figure 2.11 gives the variation of resistance in spot welding. R
2
and R
6
are resistance
between electrode tip and sheet; R
4
is the surface contact resistance; R
3
and R
5
are
sheet individual resistance. Dynamic resistance is frequently referred to as good
process variable for monitoring resistance spot weld quality.

Figure 2.11: Dynamic Resistance
Electrode
R1 X1
X2
R2
R3
R4
R5
R6

Na and Park [7] proposed a hybrid approach to predict dynamic resistance. They
suggested to explicitly include the effect of micro contacts for calculating the
distribution of electric potential and temperature in resistance spot welding process.
The contamination film was assumed to be the insulating oxide layer, which is
uniformly distributed in the contact interface. Moreover it was assumed that the oxide
contamination layer is so brittle that it is crushed to pieces as soon as contacting
pressure is applied.

The broken layers were then assumed to be of a certain size and were distributed in
the contact surface at regular interface. The dynamic resistance was then defined as
the value of voltage drop between two electrodes divided by overall current flowing
through work piece. The results showed for first two cycles, the dynamic resistance
decreased very steeply and reached its minimum value. This was taken due to effect
of the contamination films and fresh asperities existing in the work piece to work
piece interface and/or work piece to electrode interface. The study also revealed that
in the low force range it is not sufficient to consider only the contamination film,
because of the surface inconsistence which prevents full contact. In the relatively high
contracting force range, considerably satisfying results were obtained.

Mechanical characteristics of resistance spot welding machines, such as stiffness,
friction, and moving mass have complex. These factors were systematically
investigated by Tang, Hou, Zang, Feng and Kimchi [11] through experiments. These

mechanisms of influences were explored by analyzing process signature, such as
welding forces and electrode displacement and other process characteristics, such
aselectrode alignment. They recommended high stiffness as machine mechanical
characteristics and concluded its positive influence on expulsion prevention and weld
quality.

The effect of tip force on weld quality and electrode life was studied by Hirsch[12]
high electrode force reduces heat created within the nugget area to greatly reduce
penetration. This results in low tensile strength welds that have poor weldability. He
also suggested insufficient force at the electrode creates conditions that produce
inconsistent welds. Low electrode force causes high localized heating at the electrode
tip to burn away copper and thus greatly increases the electrode contact area.

Nied [5] introduced an electrically, thermally and structurally coupled axisymmetric
model considering temperature dependent properties and joules heating for squeeze
and weld cycle. The displacements and stress distribution of electrode and work piece
were illustrated. The temperature dependency of contact resistance was not
considered. Gould [8] studied nugget development during resistance spot welding.
Nugget thickness calculated by finite element analysis was compare with the
measured data. The analysis scheme was modeled by one dimensional heat transfer
and considered the temperature dependent contact resistance and material properties.
Cho and Cho[9] presented a theoretical basis for thermal behavior of resistance spot
welding. Finite difference models were developed to predict the temperature and
voltage distribution during nugget formation, incorporating the thermal-electrical
interaction at the faying surface. The thermoelectric interaction at weldment interface
on internal heat generation was undertaken. Based on the model, time behavior of the
temperature field in the weldment, nugget diameter growth and nugget penetration
was solved.

Cha and Na [10] obtained residual stresses from electrical-thermal structural analysis
and the parameters that effect residual stresses. The results were focused on the
residual stress around the nugget edge because the tensile residual stress around it
contributes most in increasing the maximum stress of spot welded structures.

Equations for residual stresses were developed in terms of welding conditions
andwere used to find welding conditions that minimize residual stresses. The results
were helpful not only when the mean stress effect on fatigue strength needs to be
calculated, but also when the maximum stress is to be obtained considering the
residual stress.

2.4 SUMMARY

Spot welding is metal joining process and widely used in sheet metal industry. The
basic resistance welding process has not appreciably since long time. At its most, it
consists of passing electrical current through two or more layers of the metal that are
being held together by force, when current passes through this sandwich, the metal
is heated and coalesces. The process is controlled combination of forging and melting.
Temperature along the interfaces in the welding processes is the important aspects of
welding. Various studies are conducted to study thermal effects during the processes.
The main consideration during the spot welding is formation of correct nugget. The
works have been done to study the effects of weld parameters on nugget growth
experimentally and also using finite element method.

CHAPTER 3

SPOT WELDING FACTORS

3.1 SPOT WELDING MACHINE

In making a resistance spot weld, the machine used must deliver the correct amount of
current, localize it at the point where welding is desired and apply the proper pressure at
the correct time. The transformer and electrode system must also be cooled due to the
heat generated using high current in resistance welding. Therefore, a resistance welding
machine is basically composed of following systems:

Electrical system
Mechanical system
Control system
Cooling system

3.1.1 ELECTRICAL SYSTEM

The electrical system of resistance welding machine supplies electrical power to the
weld in high current and low voltage, the major parts are the welding transformer and
the secondary circuit including the electrodes which conduct the welding current to
the work. According to the electrical operation, the welding machines are classified as
AC, DC and CD machines, which utilize alternating current, direct current and current
from capacitor discharge, respectively.

3.1.2 MECHANICAL SYSTEM

The mechanical system of resistance welding machines is used to hold the workpiece
and apply the welding force. For all types of welding machines, the mechanical
system and secondary circuit designs are essentially the same, the major parts include
pneumatic or hydraulic mechanisms, machine frame and some associated accessories.

A general overview of each part is shown in Fig. 3.1. The following sections will
mainly focus on the characteristics of resistance welding machines with air-operated
mechanism and hydraulic mechanism.

3.1.3 AIR-OPERATED MACHINES

Air-operated machines are the most popular type. It is mainly used for small size of
machines.

Figure 3.1: Overview of mechanical system of spot and projection welding
machine
A - air or hydraulic cylinder, B ram, C - spot welding attachment, D - upper platen
E - lower platen,F knee, G - flexible conductor, H - transformer secondary, J - knee
support

The air machines can operate very rapidly and are easily set up for welding, providing
much faster electrode follow-up because of the compressibility of air. The fast
electrode follow-up is particularly important when spot and projection welding
relatively thin sections. In addition, air-operated machines are low in noise during the
operation.

3.1.4 CONTROL SYSTEM

The objectives of the control system of welding machines are basically to:
- Provide signals to control machine actions, making the machine working
automatically following the sequence of welding steps.
- Start and stop the flow current to the welding transformer.
- Control the magnitude of the current.

Furthermore, in recent years, the new-developed control systems even have the
functions of on-line monitoring the welding quality. In servo-driven spot weld gun,
the force is also controlled using the feedback control system.

3.1.5 COOLING SYSTEM

Most resistance welding machines use water cooling, the elements needed cooling
include: SCR, secondary coil of welding transformer, welding circuit and electrodes.
A closed-loop cycling system with distillation water is commonly used as the cooling
system for resistance welding equipments.

3.1.6 A.C. RESISTANCE WELDING MACHINE

Most resistance welding machines are single-phase AC machines. This is the type of
machine most commonly used, because it is the simplest and least expensive in initial
costs, installation and maintenance. The electrical circuit is shown in Fig. 3.2 and Fig.3.3
The power from the single phase of main power is applied to the primary side of the
welding transformer through a switch (anti-phase dual silicon-controlled rectifiers),
converted by the transformer and output high current (low voltage) on the secondary side.

In AC resistance welding, the welding current flows with positive and negative half
cycles, there is zero heat or current between these two half cycles. This is called cycling,
which can cause some undesirable effects in welding smaller and thinner parts, where the
weld time is typically under 3 cycles, because the weld may cools effectively between the
half cycles, this will result in loss of the heat required to make a good weld.

Another negative effect of cycling is that when the heat is not applied constantly
throughout the duration of the weld, the nugget growth can be irregular. Variations in the
weld nugget are directly related to the quality and strength of a weld. Other AC
disadvantages are unbalanced line loading and lower power factors due to the inherent
inductive reactance in the machine.

3.1.7 A.C. SPECIFICATION OF RESISTANCE WELDING MACHINE

For spot welding process a spot welding machine with rated configuration of rated
capacity 15KVA, the maximum short circuit secondary - 18 kAmps, with a supply
voltage of 415V and the rated frequency 50/60 Hz, control panel for the welding current,
welding time and squeeze time controller was used. The maximum electrode force is
3000 N (pneumatic loading). The welding electrodes were made of copper alloy with a
conical shaped tip surface geometry. All the welding parameters were set to obtain a
reasonably good spot weld nugget. It should be noted here that the weld lobe was not
constructed in this study by varying the welding current and welding time during the spot
welding process.

Figure 3.2: Various parts of RSW machine

The variation was performed to obtain the maximum possible weld nugget diameter that
the spot welding machine can produce. After performing the spot welding operation, the
obtained spot weld nugget diameter was checked. This procedure is described in the next
section.

Figure 3.3: Resistance spot welding machine

3.2 SPOT WELD NUGGET DIAMETER

The most critical dimension to be determined for this study is the spot weld nugget
diameter since it plays the vital role in determining the mode of failure of the welded
joint. Several standards are set to determine the nugget dimension for a particular
sheet metal thickness. Several researchers have also proposed mathematical equations
for the calculation of a desired spot weld nugget diameter. Most of these standards
and calculations were based upon the lap shear coupon configuration. Hence, the
desired spot weld nugget diameter in this study is calculated for the lap shear coupon
configuration.

Ewing et al. (1982) and Chao (2003) have reported such standards concisely.
American Welding society (AWS), American National Standards Institute (ANSI)
and Society of Automotive Engineers (SAE) jointly recommended the size of the spot
weld nugget diameter for steel according to the following equation.

D = 4 t (2.1)

Where D and t are the nugget diameter and sheet thickness in mm respectively.
Apart from the above mentioned equation, the following two equations are widely
used in the industry for the minimum nugget diameter and nominal nugget diameter
respectively.

D = . 9( 1. 5t . 7)
1
2
(2.2)
D = . 8( 1. 5t . 7)
1
2
(2.3)
Where D and t are in inch respectively. All these formulas provide a general idea
about the dimension but they cannot distinguish between the failure modes of the spot
weld nugget. VandenBossche (1977) first introduced such kind of formula to identify
the nugget diameter in conjunction with the material property and coupon width
value. The formula he proposed for transition weld diameter is given in the following
form.

D
t
= j. 54
S
YPM
1.54S
YPM
+572MP
a
w
t
[
1
2
+3. (2.4)

Where D, w and t are the nugget diameter, coupon width and sheet thickness in
mm respectively. S
YPM
is the yield stress of the base metal. Chao (2003) later
proposed a very simple form of equation to predict the critical nugget diameter for the
failure from the interfacial mode to nugget pull out mode.

The critical nugget diameter proposed by Chao (2003) is
D = 3.41t
3
4
(2.5)

Where D and t are the nugget diameter and sheet thickness in mm.

D
c
= . 54t
3.22
+8.48j
H
Max
H
M|n
[
-1.24
(2.6)

Where t is the thickness of the sheet metal (in mm), H
max
and H
min
are the
maximum and minimum hardness value of the spot weld joint area. Possible causes
for the undersized weld issues are:

Dirty material
Electrode misalignment
Insufficient cooling
Weld current low
Weld force high
Weld time short
Wrong tips.

3.3 SPOT WELD NUGGET DIMENSION CHECKING

The coupons were checked after spot welding them together to ensure the desirable
nugget diameter was attained. Welding quality is primarily depends on the nugget
size. There are two critical nugget size parameters. The first is the nugget diameter
which is represented by the width of the nugget at the faying surface. The second is
the penetration depth which is the overall height of the nugget at its center. The figure
below is the schematic view of the welding nugget diameter.

Figure 3.4: Schematic view of nugget size diameter

During the welding process a large amount of heat is applied on the material, it
undergoes severe changes in its micro structural format. So the hardness profile
changes along the radial axis of the spot welded (nearly) circular nugget changes
according to the applied heat.

The three separate zones namely the spot welded nugget, the heat affected zones and
the base metal are clearly identified in the following figure. These three zones have
different levels of hardness values. So investigation of the hardness profile will
definitely reveal the actual dimension of the spot weld nugget.

Figure 3.5: Different zones of weld nugget.

CHAPTER 4

EXPERIMENTAL STUDY

The material used in this project work is Stainless steel sheet metal, with a thickness
of 0.8 mm and 1.0 mm for both the thicknesses the length of the coupon is 80 mm and
width of the coupon is 40 mm. The experiments involved joining of two layer of sheet
metal. The parameters vary on welding current, electrode force, welding time and
sheet layers.

Resistance spot welding conditions include three parameters which are force (axial
squeezing force), electric current and welding time. The welding conditions for the
two pieces of Stainless steel sheets with0.8 mm and 1.0 mm thickness of each work
piece are shown in below Tables. Four levels of welding current (3.0 kA, 3.5 kA,
4.0 kA,4.5 kA) were selected in experiments. The welding time is indicated by current
cycles which are widely used for both alternative and direct current. One cycle is 0.02
seconds and alternative current was used in the experiments. The maximum cycles of
welding current were 75cycles (time is 1.5sec), 100cycles(time is 2.0 sec), 125cycles
(time is 2.5sec) and 150 cycles (time is 3.0 sec). The axial force applied to electrodes
was 1.6kN, 1.8kN, 2.0kN and 2.2kN. The nugget diameter d and tensile shear
strength is measured in all the experiments with different welding conditions.

4. 1 EXPERIMENTAL PREPARATION

To investigate the influence of welding parameters on weld quality of RSW for
Stainless steel sheets with thickness of 0.8mm and1.0 mm were used in this study.
The welding equipment is composed by a Pneumatic gun and medium frequency
Alternating current welder. The character of the Pneumatic gun could be helpful for
the accuracy of the electrode force and improve the experimental results. The welding
parameters (welding time and welding current) for Stainless steels with different
thickness according to the standards of American welding society (AWS).

The weld quality including weld nugget size and tensile shear strength could be
measured by Peel test and UTM .

Figure 4.1 Experimental setup for RSW
Table 4.0:
Specifications of the Spot WeldingMachine
Make India
Rating 15KVA
No load Secondary Voltage 5.14V
Supply Voltage 415V,50Hz
Throat Depth 470mm
Throat gap 230mm
Air Pressure 6bar
Force 150Kgf 300Kgf

Figure.4.2: Flat Rectangular bottom Electrode

Figure.4.3: Flat Rectangular bottom Electrode

Figure.4.4: Assembled flat Rectangular bottom Electrode

Figure.4.5: Spot weld being carried out on Rectangular bottom Electrode

Figure.4.6: Spot weld being carried out on Rectangular bottom Electrode

Figure.4.7: Sample coupons of 0.8 mm & 1.0 mm thickness of SS 304 for spot
welding

Table 4.1: Spot Welding process Parameters and their values for 0.8mm and
1.0mm thickness of sheet metal with constant welding Time

S. No Sheet metal
Thickness
(mm)
Spot Welding Parameters
Welding Current in
kA
Electrode
Force
kN
Welding time
in
cycles
1. 0.8
(40mmx80mm)
3.0 1.6 75
2. 1
(40mmx80mm)
3.0 1.6 75

Figure.4.8: Sample coupons of 0.8 mm & 1mm thickness of sheet metal before
spot welding (75 cycles)

Figure.4.9: Sample coupons of 0.8 mm & 1.0 mm thickness of sheet metal after

1mm thickness of sheet metal with constant welding time (75cycles)

S. No

Thickness
Of
Plate(mm)
Electrode
Force (kN)
Welding
Current (kA)
Welding time
(Cycles)
Nugget
Diameter (mm)
1 0.8 1.6 3.0 75 8
2 1.0 1.6 3.0 75 9

Table 4.3:Spot Welding process Parameters and their values for 0.8mm and

S. No Sheet metal
Thickness
(mm)
Welding Current in
kA
Electrode
Force
kN
Welding time
in
cycles
1. 0.8
(40mmx80mm)
3.5 1.8 100
2. 1
(40mmx80mm)
3.5 1.8 100

spot welding (100cycles)

Figure.4.11: Sample coupons of 0.8 mm & 1mm thickness of sheet metal after

1.0mm thickness of sheet metal with constant welding time (100cycles)

S. No Thickness
Of Plate
(mm)
Electrode
Force (kN)
Welding
Current (kA)
Welding time
(Cycles)
Nugget
Diameter (mm)
1 0.8 1.8 3.5 100 8.5
2 1.0 1.8 3.5 100 9.5


S. No Sheet metal
Thickness
(mm)
Welding Current in
kA
Electrode
Force
kN
Welding time
in
cycles
1. 0.8
(40mmx80mm)
4.0 2.0 125
2. 1
(40mmx80mm)
4.0 2.0 125

Figure.4.12:Sample coupons of 0.8 mm & 1mm thickness of sheet metal before



S. No Thickness
Of Plate
(mm)
Electrode
Force (kN)
Welding
Current (kA)
Welding time
(Cycles)
Nugget
Diameter (mm)
1 0.8 2.0 4.0 125 9
2 1.0 2.0 4.0 125 10

S. No Sheet metal
Thickness
(mm)
Welding Current in
kA
Electrode
Force
kN
Welding time
in
cycles
1. 0.8
(40mmx80mm)
4.5 2.2 150
2. 1
(40mmx80mm)
4.5 2.2 150




S. No Thickness
Of Plate
(mm)
Electrode
Force (kN)
Welding
Current (kA)
Welding time
(Cycles)
Nugget
Diameter (mm)
1 0.8 2.2 4.5 150 9.5
2 1.0 2.2 4.5 150 10

Figure.4.16: SPOT WELDED SAMPLE FOR PEEL TEST

4.2 PEEL TEST

Figure.4.17: Peel Test being carried out for measuring the Nugget Diameter

Figure.4.18: Peel Test being carried out for measuring the Nugget Diameter

Figure.4.19: Spot Welded Work Pieces after Peel Test

4.3 SHEAR TENSILE TEST

Tensileshear strength is an important measure of welding quality in RSW. Therefore,
in this research tensile shear strength has been selected to describe the mechanical
properties of spot weld. Referring to Fig. 1 , there is an eccentricity D between two
tensile axes of the overlap joints. The tensile stress and shear stress are both playing a
role during tension test to spot weld because of the eccentricity. A tensile shear test
specimen was spot welded for each of the given welding conditions mentioned above.
The specimens were prepared according to ISO. In order to increase the accuracy and
the confidence level, the experiment related to each of the parameters combinations
was carried out three times and their average value reported as the strength related to
this parameters combination. The tensile shear tests were carried out at a crosshead of
20 mm/min with a universal testing machine. During the tests, three types of breaking
failure were observed: (1) separation; (2) knotting; (3) tearing. Samples of them are
shown in Fig.4.24

Figure.4.20: The tensileshear strength test

Figure.4.20a: Spot welded sample for shear tensile test

Figure.4.20b: Spot welded sample for shear tensile test

Figure.4.20c: Spot welded sample for shear tensile test

Figure.4.20d: Spot welded sample for shear tensile test

Figure.4.21: Shear Tensile Test being Carried out

Figure.4.22: Shear Tensile Test being Carried out

Figure.4.24a :The tensileshear strength test (1) separation

Figure.4.24 b :The tensileshear strength test (2)shearing

Figure.4.24 c :The tensileshear strength test (3) tearing

Table 4.9: Experimentally obtained values of Nugget diameter and Shear Tensile
Test (75 Cycles)

S. No Thickness Of
Plate(mm)
Electrode
Force
(kN)
Welding
Current
(kA)
Welding
time
(Cycles)
Nugget
Diameter
(mm)
Ultimate
Load (kN)

1 0.8
(40mm x 140mm)
1.6 3.0 75 8 10.78
2 1.0
(40mm x 140mm)
1.6 3.0 75 9 10.19

Tensile Test (100 Cycles)

S. No Thickness Of
Plate (mm)
Electrode
Force
(kN)
Welding
Current
(kA)
Welding
time
(Cycles)
Nugget
Diameter
(mm)
Ultimate
Load (kN)

1 0.8
(40mm x 140mm)
1.8 3.5 100 8.5 10.10
2 1.0
(40mm x 140mm)
1.8 3.5 100 9.5 10.19


S. No Thickness Of
Plate (mm)
Electrode
Force
(kN)
Welding
Current
(kA)
Welding
time
(Cycles)
Nugget
Diameter
(mm)
Ultimate
Load (kN)

1 0.8
(40mm x 140mm)
2.0 4.0 125 9 10.00
2 1.0
(40mmx 140mm)
2.0 4.0 125 10 9.90


S. No Thickness Of
Plate (mm)
Electrode
Force
(kN)
Welding
Current
(kA)
Welding
time
(Cycles)
Nugget
Diameter
(mm)
Ultimate
Load (kN)

1 0.8
(40mm x 140mm)
2.2 4.5 150 9.5 9.90
2 1.0
(40mm x 140mm)
2.2 4.5 150 10 9.90

CHAPTER 5

INTRODUCTION TO SIMULATION OF RSW PROCESS

This project work built a two dimensional finite element (FE) model for resistance
spot welding (RSW) process of Stainless steel with two sheets assemblies on practical
aspect of industry applications. The thermal-electrical coupling method was
implemented to investigate transient thermal characteristics during resistance spot
welding history with commercial software code, namely ANSYS. Temperature
dependency electrical and thermal material properties, phase change as well as
convection boundary condition were taken into consideration throughout the coupling
procedure. The temperature distribution changes of two sheets assemblies were
obtained and transient thermal characteristics were analyzed during RSW thermal-
electrical coupled history. Moreover, nugget formation was particularly viewed and
discussed under appropriate welding contact condition and other experimental
physical parameters.

The RSW process has been widely employed in sheet metal fabrication owing to its
high speedsuitability for automation and inclusion in high production assembly
lines with other fabricating operationsIt is a complex process in which coupled
interactions exist between electrical, thermal mechanical, metallurgical phenomena,
and even surface behaviours. In order to well understand the mechanism of such a
complex processnumerous researches have been performed on all kinds of welding
conditions and materials, using both theoretical and experimental methodsIn recent
yearsnumerical method provides a powerful tool in studying these interactions, and
much related work has been done on the numerical modelling of RSW. In particular,
the FEA, which can dea1 with nonlinear behaviours and complex boundary
conditions, has become the most important method for the analysis of RSW process

Nied developed the first FEA model for RSW process, investigated the effect of the
geometry of electrode on work piece and predicted the deformation and stresses as a
function of temperatureHowever, the model developed was restricted to elastic
deformation, and not calculated the contact areas at the electrode work piece and
faying surfaceFurthermoremany researchers developed more sophisticated FEA
models that considered temperature dependent material properties, contact status,
phase changing, and coupled field effects on the simulation of RSW. To solve a
common coupled problem, the iterative solution procedure is an often adopted
method, in which the equations describing different domains are solved separately
using dedicated solvers, and the data exchanged at every time step until convergence
of iteration is reached.

This information is transferred forward to the next time step and the numerical
scheme of study repeated. This iterative method can also be employed to simulate the
interactions between coupled electrical, thermal, and structural fields of the RSW
process. Initially the stress field and contact status are obtained from the thermal-
mechanical analysis, and then the temperature field is obtained from the fully coupled
thermal-electrical analysis based on the contact area at the electrode work piece
interface and faying surfaceThe calculated temperature field is then passed back to
the thermal-structural analysis to update the stress field and contact status

Even if the iterative method can provide the temperature field, the electric potential
field, the stress and strain distributions in one calculation, the modelling of transient
processes with such a methodology would probably require tremendous computing
time. The objective of this project work is to develop a multi-coupled method to
analyse the thermal and mechanical behaviours of RSW process, reduce the
computing time with the minimum loss of accuracy and get more adequate
information of the process, improve the quality monitoring and process control of
RSW.

5.1 SIZE OF ELECTRODES

Fig.2 gives the size of electrodes used in this project. The radius of electrode Rb is 15
mm and the radius of cooling water hole Rw is 5 mm respectively. Both the height of
theupper electrode Hel and the height of lower electrode He2 are40 mm. The distance
between working surface and coolingwater hole of upper and lower electrodes, Hwl
and Hw2, are20 mm. The length and width of rectangular electrode tip are 2L and 2B
respectively. The angle Kl is 30
o
and K2 is 30. The length and width of workpiece are
80 x 40 mm, and the depth is 0.95 mm. For 0.8 mm+0.8 mm or 1.0 mm+1.0 mm
workpieces of stainless steel, the nugget diameter of resistance spot welding with
conventional electrode is about 4.0 mm-4.5mm. Considering the actual welding
conditions, the size of rectangular electrode is set 60mm 70 mm in order to raise the
nugget length.

5.2 COMPUTATIONAL MODEL

In this project, the objects to be analyzed are composed of two AISI 304L-type
stainless steel sheets welded by a resistance spotwelding machine. Due to the
axisymmetric geometry and loading of the electrodes and the workpieces, the steel
sheets and electrodes were modeled taking advantage of a two-dimensional
axisymmetric model, as shown in Fig. 5.1. To solve the governing equations of the
model, a finite element based program, ANSYS, has been employed.

Figure.5.1: The size of electrodes

Table 5.1: Welding parameters for the simulation

Electrode
diameter(mm)
(Upper)

Electrode
size(mm)
(Bottom)

Electrode
force
(kN)

Welding
current
(kA)

Time (ms)

Squeezing Welding Hold
11mm 60mm x 70mm 1.5-2.5 3.0- 4.5 kA 100 1000 300

5.3. GOVERNING EQUATION

The constitutive equation of the materials based on thermo-elasticplastic theory is
given by:

[d] = [D
ep
][d] [C
th
]dT

Where

[D
ep
] = [D
e
] + [D
p
]

in which, [D
e
] is the elastic stiffness matrix, and [D
p
] is the plastic stiffness matrix,
[d] is the infinitesimal strain tensor, [d] is the infinitesimal stress tensor, and [C
th
]
denotes the thermal stiffnessmatrix.The stress equilibrium equation is given by:

ij
+b
i
= 0

where b
i
is the body force and
ij
is the stress tensor.

Table 5.2: Boundary conditions
Mechanical Thermal Electrical Boundary
P (applied pressure) 25
o
C I (applied current) Top of upper electrode
U
z
= 0 25
o
C V = 0 Bottom of lower electrode
= 0 25
o
C I = 0 Water channel
U
r
= 0 Adiabatic I = 0 Symmetry line
= 0 Air cooled I = 0 Lateral surfaces

5.4 HEAT TRANSFER ANALYSIS

Heat transfer in resistance spot welding process involves convective heat transfer as
well as heat conduction in bulk of the sheet-electrode system. The transient heat flow
in resistance spot welding process has been modeled as a case of axisymmetric heat
conduction problem. The governing differential equation for the heat transfer problem
is:

t
T
= +

z
1
+

1
.
c
c
c
c
c
c
c
c
c
c
c s Q
z
T
K r
r r
T
K r
r r
|
.
|
\
|
|
.
|
\
|
(1)
Where s, c and K are density, specific heat and thermal conductivity respectively and r
and z are radial and axial coordinates. All the material properties are considered to be
temperature dependent. The term Q
.
refers to the rate of internal heat generation per
unit volume within the boundaries of the region of analysis. This particular term
accounts for the Joule heating due to bulk resistivity of electrodes and sheets and
contact resistance of electrodesheet interfaces and faying surface between the sheets.

Electrical Field Analysis

The current density distribution in the sheet-electrode geometry (in two-dimensional
cylindrical coordinate system) can be represented by the following relationship,

0

1

z
1
+

1

1
=
|
|
.
|
\
|
|
|
.
|
\
|
z
r
r r
r
r r c
c
c
c
c
c
c
c J J
(2)

where, is the electrical resistivity and J is the current density vector. The electrical
resistivity is considered temperature dependent in the present work.

The bottom of the lower electrode was set to be zero for the reference electrical
potential. The imposed boundary conditions are presented in Table 5.2 and Fig. 5.2. In
this study the amount of convection has been taken as 15 W/m2 K. This boundary
condition has been included in the model for lateral surfaces (see Table 5.2).
However, it should be mentioned that in RSW process the radiation and convection
with air have small effect on cooling compare with conduction. This is due to small
heating zone and short period of the spot welding process.

Figure. 5.2: Schematic of the (a) electro-thermal boundary conditions, and (b)
mechanical boundary conditions.

Figure.5.3: Boundary conditions

5.5 BOUNDARY CONDITIONS

Since a 50 Hz AC welding machine was used in this study, a 50 Hz sine wave
electrical current flow was assumed to be uniformly distributed at the top surface of
the upper electrode and was permitted to flow across the contact areas at both the
electrode-workpiece interfaces and faying surface between sheets and, eventually
reaching the bottom surface of the lower electrode. The convective heat transfer
coefficient of cooling water is3800 W/(m z 'C), and the water temperature is 20 'C .
Natural convective heat transfer coefficient of air around workpiece and electrode is
25 W/(mz ,C),and the air temperature is 20 'C. The model symcenter line is thermal
insulation boundary and the initial temperature of model is set 20 'C.

5.5.1 MECHANICAL BOUNDARY CONDITIONS

Uniform load was applied at the top of the copper electrode during welding and
holding cycle. The electrode was removed at the end of the holding cycle. At the
faying surface between the electrode and the workpiece, a contact 172 element was
used. At the faying surface between workpiece and workpiece, the vertical
displacement of the part of faying surface under electrode was set to zero, and a
subroutine program was used to determine if the other part of faying surface is under
contact or not. If some nodes are under contact and are under pressure stress, a zero
vertical displacement was applied here.

5.6 MATERIAL PROPERTIES

The steel sheets in this study were AISI type 304 stainless steel with chemical
composition presented in Table 1, and the electrode was taken as copper. Tables 5 and
6 show temperature-dependent physical and mechanical properties of the materials
used for both electro-thermal and thermo-mechanical analysis.

Figure. 5.4: The finite element solving algorithm used for simulating the RSW
process

5.7 SOLVING PROCEDURE

The welding process starts with analyzing the squeeze cycle in which the electrode
force is applied to the electrodes. The results of this mechanical analysis include
initial deformations and contact area, which serve in electro-thermal analysis. In this
stage, the temperature distribution by the Joule heating is calculated for an increment
from the fully coupled electrical thermal finite element analysis.

In the electrically thermally coupled analysis after the electrical and thermal
boundary conditions applied to the model, the solving routine performs the
calculations of Joule heating at the workpieceworkpiece and electrodeworkpiece
faying surfaces, as well as in the base material and electrode. As a result, the
temperature distributions are obtained in the first increment and sent to the
mechanical analysis as a nodal thermal load. Contact pressure and deformations are
the results of mechanical analysis that obtain a new contact condition. So, the
mechanical results are given to electro-thermal analysis to update contact conditions
for the next increment analysis. This loop continues until the welding time is finished.
Commercial finite element code ANSYS is used to follow this procedure.

It is worth noting that in the mechanical analysis, elements of type Plane 42 and in
the electro-thermal model, elements of type Plane 223, having capabilities of
thermal, electrical and thermal-electrical-analyses, were used. There were three
contact areas in them odel, two contact areas representing the electrodesheet
interface and one representing the sheetsheet interface. The contact pair elements
Targe169 and Conta171 were employed to simulate the contact areas. In the finite
element analysis 2507 elements and 8051 nodes for 0.8mm thickness plate and 2635
elements and 8439 nodes for 1.0mm thickness plate have been employed.

In order to investigate the mesh size effect, the thermal results are compared to those
of a finer mesh comprised of 2507 elements of the same types, for a welding current
of 3.0 kA and a welding time of 75 cycles. The investigation shows that the maximum
differences in the peak temperatures are less than 1.86%. As the differences are
negligible, the primary mesh is admitted and used to save the computational time.

Table 5.4: Thermal and electrical properties of of the employed SS304 and
copper electrodes.
Temperat
ure
C
Thermal
conductivity
J/m.C
Electrical resistivity
.m

Contact
resistivity
.m
2
10
-7

Specific Heat
J /(kg.C)
Stainless
Steel
Copper
Electrode
Stainless
Steel
Copper
Electrode
Faying surface Stainless
Steel
Copper
Electrode
20 14.6 390.3 0.604 26.4 2.38 462 397
93 380.6 30.0 2.31 402
100 15.1 0.702 2.25 496
200 16.1 370.1 0.774 40.0 2.12 512 419
300 17.9 0.858 1.93 525
316 355.1 50.5 1.79 431
400 18.0 0.922 1.31 540
427 345.4 61.9 440
538 334.9 69.9 0.567 465
600 20.8 1.001 577
649 320 80.0 477
760 315.5 89.8 0.492
800 32.2 1.120 0.417 604
871 310.3 94.8 0.342
982 305 99.8 502
1200 1.210 676
1300 33.7 1.280 692
1480 120 700

Table 5.5: Physical and mechanical properties of the employed SS304 and copper
electrodes.
Tempe
rature
C
Youngs
Modulus
G P
a

Yield stress
M P
a

Poissons
ratio
Coefficient of
thermal
expansion
(C-1 x 10
-5
)
Density
Kg/m
3
Stainl-
ess
Steel
Copper
Electr-
ode
Stainl
-ess
Steel
Copper
Electr-
ode
Stainl-
ess
Steel
Copper
Electr-
ode
Stainl
-
essSteel
Copper
Electr-
ode
Stainl-
ess
Steel
Copper
Electr-
ode
20 198.5 124 319 0.294 1.70 1.65 7900 8900
93 105 1.67
100 193 279 0.295 1.74 7880
200 185 93 238 0.301 1.80 1.71 7830
300 176 217 83 0.310 0.32 1.86 7790
316 82 1.75
400 167 198 0.318 1.91 7750
427 55 1.78
538 38 1.84
600 159 177 0.326 1.96 7660
649 25 1.85
760 16 1.89
800 151 112 0.333 2.02 7560
871 14 1.93
982 7
1200 60 32 0.339 2.07 7370
1300 20 19 0.342 2.11 7320
1480 10 8 0.388 2.16 7320

Table5.6: Element types and degree of freedom options
Analysis Solid Contact element type
Degree of freedom
(for contact
element)
Electrical-Thermal PLANE 223 CONTACT172/TARGET 169 TEMP, CURRENT
Thermo-Structural-
Electric
PLANE 223 CONTACT172/TARGET 169 UX, UY

Figure 5-5: The model of spot welding with rectangular electrode.

5.8 WELDING PARAMETERS AND CONTACT RESISTANCE

The welding parameters used in this analysis arewelding current 50 Hz sine wave
AC current of 3.0 kA,3.5 kA,4.0 kA and 4.5 kAweld time, 75cycles (1.5 S),100
cycles(2S), 125cycles(2.5S), 150cycles(3S); electrode force1.6kN, 1.8kN,
2.0kN,2.5kN;hold time,3 cycles (0.06S). The thermal, electrical and mechanical
properties of electrode and work piece are given in Table 5.3 and Table 5.4. Because
the materials are subjected to a wide range of temperatures, most of these properties
are considered as temperature dependent.

The most important property in the simulation of RSW process is the contact
resistivity of faying surface. Generally speaking, the contact resistivity is a dependent
function of contact pressure, temperature, and average yield strength of two contact
materials. It is pointed out by Vogle M, and Sheppard S., that the contact resistance
decreases as the contact pressure increases. Babu S.S., Santella M.L.developedan
empirical model is for the pressure and temperature dependence of electrical contact
resistance, a curve fitting procedure is used and the desired relationship between
contact resistance and pressure and temperature is established

During the RSW process, the contact resistivity distribution influences the current
density pattern, which affects the temperature field through Joule heating while, the
temperature field then influences the mechanical pressure distribution through thermal
expansion, related to the interface resistivity. Therefore, this is a highly non-linear
problem involving the complex interaction between thermal, electrical and
mechanical phenomena. To simplify the problem, any researchers take the contact
resistivity as a function of temperature. This simplification is reasonable because,
firstly, the load is constant in a specified RSW process; secondly, the yield strength of
the materials, which determines the contact status in the contact area, is essentially
influenced by temperature with this simplification, the computing time can be greatly
reduced. Therefore, in the present work, the temperature dependent contact resistance
is imposed on the faying surface.

Figure 5-6 : 2D Axisymmetric Quarter meshed model geometry

5.9 SIMULATION OF STAINLESS STEEL SHEETS OF 0.8mm &1.0mm
THICKNESS

Table 5.7: Employed spot welding Parameters for simulation of 0.8mm and
1.0mm thickness sheet metal with constant welding Time

Sample
Number
of the
Simulation
Sheet Metal
Thickness
(mm)
Selected Spot Welding Parameters for
Simulation
Welding
Current
(kA)
Welding
Time
(Cycles)
Electrode
Force
(kN)
1 0.8 3.0 75 1.6
2 1.0 3.0 75 1.6

75 cycles-3.0 kA-1.6 kN (0.8mm Plate)

Fig 5.7:The predicted temperature distribution from the simulation for the
Sample1

Fig 5.8: The predicted temperature ( ) distribution graph with respect to time
in seconds (1cycle = 0.02 seconds) from the simulation for the sample 1

75 cycles-3.0 kA-1.6 kN (1.0mm Plate)

Fig 5.9: The predicted temperature ( ) from the simulation for the sample 2


Table 5.8: Measured values of Nugget diameter by Simulation of sheets
of0.8mmand 1.0mm thickness (75 Cycles)

Sample
Number
of the
Simulation
Thickness
Of Plates
(mm)
Electrode
Force (kN)
Welding
Current
(kA)
Welding
time
(Cycles)
Nugget
Diameter
(mm)
1 0.8 1.6 3.0 75 7.8
2 1.0 1.6 3.0 75 8.8


Sample
Number
of the
Simulation
Sheet Metal
Thickness
(mm)
Simulation
Welding
Current
(kA)
Welding
Time
(Cycles)
Electrode
Force
(kN)
3 0.8 3.5 100 1.8
4 1.0 3.5 100 1.8

100cycles-3.5 kA-1.8 kN (0.8mm Plate)






Sample
Number
of the
Simulation
Thickness
Of Plates
(mm)
Electrode
Force (kN)
Welding
Current
(kA)
Welding
time
(Cycles)
Nugget
Diameter
(mm)
3 0.8 1.8 3.5 100 8.2
4 1.0 1.8 3.5 100 9.2


Sample
Number
of the
Simulation
Sheet Metal
Thickness
(mm)
Simulation
Welding
Current
(kA)
Welding
Time
(Cycles)
Electrode
Force
(kN)
5 0.8 4.0 125 2.0
6 1.0 4.0 125 2.0







Sample
Number
of the
Simulation
Thickness
Of Plates
(mm)
Electrode
Force (kN)
Welding
Current
(kA)
Welding
time
(Cycles)
Nugget
Diameter
(mm)
5 0.8 2.0 4.0 125 8.3
6 1.0 2.0 4.0 125 9.8


Sample
Number
of the
Simulation
Sheet Metal
Thickness
(mm)
Simulation
Welding
Current
(kA)
Welding
Time
(Cycles)
Electrode
Force
(kN)
7 0.8 4.5 150 2.2
8 1.0 4.5 150 2.2







Table 5.14: Measured values of Nugget diameter by Simulation of sheets of
0.8mmand 1.0mm thickness (150Cycles)
Sample
Number
of the
Simulation
Thickness
Of Plates
(mm)
Electrode
Force (kN)
Welding
Current
(kA)
Welding
time
(Cycles)
Nugget
Diameter
(mm)
7 0.8 2.2 4.5 150 8.8
8 1.0 2.2 4.5 150 9.9

CHAPTER 6

CONCLUSIONS AND FUTURE SCOPE OF WORK

6.1 CONCLUDING REMARKS

The effects of electrode force on the RSW process when using a AC is investigated
using the finite element method. The variations of contact radius, current density
distribution and temperature profile at the S/S (Sheet-Sheet) and E/S (Electrode-
Sheet) interfaces, the threshold weld times and the maximum diameters of the weld
nuggets under different electrode forces are investigated. The main results are
summarized as follows:

1. The contact radius at both E/S and S/S interfaces decreases during the welding
process. Increasing electrode force increases the contact radius at both
interfaces. The minimum contact radius at the E/S interface is larger than that
at the S/S interface.

2. The welding current density distributes evenly initially, and then increases
with the decreasing of contact area at both interfaces and finally concentrates
at the molten nugget region. Increasing electrode force decreases the current
density because of the increased contact area.

3. The temperature at the central part of the workpieces is the highest at both
interfaces. A molten nugget initiates at the S/S interface center. The
temperature increase more quickly under a lower electrode force because of
the decreased contact area and increased current density.

4. The obtained nugget diamaters by experimental work are approximately equal
to that obtained by simulation work.

6.2 FUTURE SCOPE OF WORK

During the investigation undertaken in this study some other alternatives and ideas
have emerged but unfortunately not all these could be investigated in this study.

These alternative suggestions are:

1. The need to investigate the effect of other types of materials and thickness on
the resistance spot welding process and to develop model(s) for predicting
weld quality for such conditions. This will help confirm the effect of material
types and changes in material thickness on weld quality and will give
flexibility in the selection of materials types and thickness for use in the
resistance spot welding.

2. There is the need to investigate and model the relationship between the failure
modes of the welded samples to shear stress and the torque angle at the point
of failure. This is because resistance spot welds under shear stress fails at
different angles. A model should be used to establish these relationships and to
predict the shear stress and torque angle at which a spot weld can fail.

3. It is recommended that this study to be continued with other parameters such
as electrode size, materials, squeezing time and welding force. It is also
recommended that various types of electrode meshing shall be investigated to
determine their effect on nugget development and formation.
4. Through the research of this project, in order to receive different material can
be modified by welding parameters in the practical application in future,
welding parameters in the model, obtain different welding without a lot of
physical experiment, greatly reduce the cost and improve the economic
benefit, and for the future of welding standard for reference.

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An Experimental Study and Simulation of Resistance Spot Welding With Rectangular Electrode

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An Experimental Study and Simulation of Resistance Spot Welding With Rectangular Electrode

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AN EXPERIMENTAL STUDY AND SIMULATION OF

RESISTANCE SPOT WELDING WITH

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