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TECHNICAL PAPERS

Dynamic Electrode Force and Displacement in Resistance Spot Welding of Aluminum

[+] Author and Article Information
C. T. Ji, Y. Zhou

Department of Materials Engineering, Nanchang Institute of Aeronautical Technology, Nanchang, Jiangxi, 330034, P.R. Chinae-mail: ctji@niat.edu.cn

J. Manuf. Sci. Eng 126(3), 605-610 (Sep 07, 2004) (6 pages) doi:10.1115/1.1765140 History: Received July 01, 2003; Revised December 01, 2003; Online September 07, 2004
Copyright © 2004 by ASME
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References

RWMA, Resistance Welding Manual (Fourth Edition), 1989, Resistance Welder Manufacturers Association, Philadelphia, PA.
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Messler,  R.W., and Jou,  M., 1996, “Review of Control Systems for Resistance Spot Welding: Past and Current Practices,” Sci. Technol. Weld. Joining, 1(1), pp. 1–9.
Janota, M., 1974, “The Relationship Between Thermal Expansion and the Growth of a Resistance Spot Weld,” The Third International Conference on Advances in Welding Processes, The Welding Institute, Paper 40, Harrogate, 7–9 May, pp. 21–26.
Chien,  C.-S., and Kannatey-Asibu,  E., 2002, “Investigation of Monitoring Systems for Resistance Spot Welding,” Weld. J. (Miami, FL, U. S.), 81(9), pp. 195-s–199-s.
Tang,  H., Hou,  W., Hu,  S.J., and Zhang,  H., 2000, “Force Characteristics of Resistance Spot Welding of Steels,” Weld. J. (Miami, FL, U. S.), 79(7), pp 175-s–183-s.
Cho,  H.S., and Chun,  D.W., 1985, “A Microprocessor-based Electrode Movement Controller for Spot Weld Quality Assurance,” IEEE Trans. Ind. Electron., IE-32(3), pp. 234–238.
Waller,  D.N., and Knowlson,  P.M., 1965, “Electrode Separation Applied to Quality Control in Resistance Welding,” Weld. J. (Miami, FL, U. S.), 44(12), pp. 168-s–174-s.
Haefner,  K., Carey,  B., Bernstein,  B., Overton,  K., and Andrea,  M.D., 1991, “Real Time Adaptive Spot Welding Control,” ASME J. Dyn. Syst., Meas., Control, 113, March, pp. 104–112.
Fujimoto,  K., Nakata,  S., and Nishikawa,  M., 1997, “Design and Construction of a Loading System for Resistance Welding and Its Dynamic Properties: Optimization of the Loading System in High Current Density Spot Welding With a Short Energizing Time (1st Report),” Welding International, 11(5), pp. 371–377.
Irving,  B., 1995, “Building Tomorrow’s Automobiles,” Weld. J. (Miami, FL, U. S.), 74(8), pp. 29–34.
Rivett,  R.M., and Westgate,  S.A., 1980, “Resistance Welding of Aluminum Alloys in Mass Production,” Met. Constr., 12(10), pp. 510–517.
Thornton,  P.H., Krause,  A.R., and Davies,  R.G., 1996, “The Aluminum Spot Weld,” Weld. J. (Miami, FL, U. S.), 75(3), pp. 101-s–108-s.
Fukumoto,  S., Lum,  I., Biro,  E., Boomer,  D.R., and Zhou,  Y. 2003, “Effects of Electrode Degradation on Electrode Life in Resistance Spot Welding of Aluminum Alloy 5182,” Weld. J. (Miami, FL, U. S.), 82(11), November, pp. 307-s–312-s.
Hao,  M., Osman,  K.A., Boome,  D.R., and Newton,  C.J., 1996, “Developments in Characterization of Resistance Spot Welding of Aluminum,” Weld. J. (Miami, FL, U. S.), 75(1), pp. 1-s–8-s.

Figures

Grahic Jump Location
Schematic of data acquisition system
Grahic Jump Location
Nugget diameter versus welding current on the 1.5-mm-thick sheets.
Grahic Jump Location
Electrode force curves at different welding currents on the 1.5-mm-thick sheets. For each current, the first and second points marked (circled) indicate the start and end of welding current, respectively.
Grahic Jump Location
Button diameter versus weld time on the 1.5-mm-thick sheets (with the current at 30 kA)
Grahic Jump Location
Electrode force curves at different weld times on the 1.5-mm-thick sheets (with the current at 30 kA)
Grahic Jump Location
Electrode displacement curves at different welding currents on the 1.5-mm-thick sheets. For each current, the first and second points marked (circled) indicate the start and end of welding current, respectively.
Grahic Jump Location
Schematic of the change in electrode force or displacement
Grahic Jump Location
Electrode displacement versus nugget diameter on the 1.5-mm-thick (a) and 1.0-mm-thick sheets (b)

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