Technical Brief

Correlating Variations in the Dynamic Resistance Signature to Weld Strength in Resistance Spot Welding Using Principal Component Analysis

[+] Author and Article Information
David W. Adams

Research School of Engineering,
Australian National University,
Building 32, North Road,
Canberra ACT 0200, Australia
e-mail: U5013843@anu.edu.au

Cameron D. E. Summerville

Research School of Engineering,
Australian National University,
Building 32, North Road,
Canberra ACT 0200, Australia
e-mail: Cameron.Summerville@anu.edu.au

Brendan M. Voss

Research School of Engineering,
Australian National University,
Building 32, North Road,
Canberra ACT 0200, Australia
e-mail: Brendan.Voss@anu.edu.au

Jack Jeswiet

Department of Mechanical and Materials Engineering,
Queen's University,
120 Stuart Street,
Kingston K1Z 0A6, ON, Canada
e-mail: Jeswiet@me.queensu.ca

Matthew C. Doolan

Research School of Engineering,
Australian National University,
Building 32, North Road,
Canberra ACT 0200, Australia
e-mail: Matthew.Doolan@anu.edu.au

Manuscript received August 28, 2015; final manuscript received September 30, 2016; published online November 9, 2016. Assoc. Editor: Dragan Djurdjanovic.

J. Manuf. Sci. Eng 139(4), 044502 (Nov 09, 2016) (4 pages) Paper No: MANU-15-1448; doi: 10.1115/1.4034887 History: Received August 28, 2015; Revised September 30, 2016

Traditional quality control of resistance spot welds by analysis of the dynamic resistance signature (DRS) relies on manual feature selection to reduce the dimensionality prior to analysis. Manually selected features of the DRS may contain information that is not directly correlated to strength, reducing the accuracy of any classification performed. In this paper, correlations between the DRS and weld strength are automatically detected by calculating correlation coefficients between weld strength and principal components of the DRS. The key features of the DRS that correlate to weld strength are identified in a systematic manner. Systematically identifying relevant features of the DRS is useful as the correlations between weld strength and DRS may vary with process parameters.

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Fig. 1

Theoretical dynamic resistance signature adapted from Dickinson et al. [1]

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Fig. 2

Dynamic resistance signature samples with high and low resistance signatures

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Fig. 3

Weld strength values from the tensile shear tests

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Fig. 4

The first four mode shapes of signature set shape variation. Variation is exaggerated for clarity.

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Fig. 5

DRS shape with all variation not correlated to strength removed



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