Experimental and numerical analysis of shunting effect in resistance spot welding of Al2219 sheets

• Autorzy: Vardanjani M. J. , Araee A. , Senkara J. , Jakubowski J. , Godek J.

Identyfikatory

DOI

10.1515/bpasts-2016-0048

• Języki publikacji: EN

Abstrakty

EN

Few aspects of shunting effect have been studied so far. Shunting effect in resistance spot welding (RSW) occurs when the electrical current passes through the previous spot welds. Value of this current depends mostly on distance, number, and size of previous spot welds. This will cause some dimensional and metallurgical changes in welding nugget as well as heat affected zone (HAZ). In this study, shunting effect of RSW is considered by finite element method (FEM) and the results are compared to experiments performed on aluminum alloy 2219. Weld spacing together with welding current and time are considered to discover the effect of shunting current in the final quality of nugget. A three factor experiment design has been performed to find the significance of factors and interactive effects, as well as finite element model verification. Electrothermal and mechanical interactions are considered in the FEM. Experimental and numerical solutions have yielded similar results in terms of welding nugget properties. Asymmetry in electrical potential, temperature, stress distribution and geometry of shunted nugget is predicted and verified directly or indirectly. Intense effect of shunting current on nugget height, asymmetric growth of heat affected zone (HAZ) toward previous welding nugget, as well as concentration of alloying elements along grain boundaries are also discovered.

Słowa kluczowe

EN

resistance spot welding; shunting; finite element analysis; experiment

PL

odporność na zgrzewanie punktowe; analiza metodą elementów skończonych; eksperyment

• Wydawca: Polska Akademia Nauk, Wydział IV Nauk Technicznych
• Czasopismo: Bulletin of the Polish Academy of Sciences. Technical Sciences
• Rocznik: 2016
• Tom: Vol. 64, nr 2
• Strony: 425--434
• Opis fizyczny: Bibliogr. 32 poz., il., tab., wykr., fot., rys.

Twórcy

autor

Vardanjani M. J.

• Department of Welding Engineering, Warsaw University of Technology, Poland

autor

Araee A.

• Department of Mechanical Engineering, University of Tehran, Iran, Postal address: Kuy-e-Daneshgah, 14395-515 Tehran, Iran

autor

Senkara J.

• Department of Welding Engineering, Warsaw University of Technology, Poland, Postal address: Narbutta 85 St., 02-524 Warsaw, Poland

autor

Jakubowski J.

• Department of Welding Engineering, Warsaw University of Technology, Poland, Postal address: Narbutta 85 St., 02-524 Warsaw, Poland

autor

Godek J.

• Department of Welding Engineering, Warsaw University of Technology, Poland, Postal address: Narbutta 85 St., 02-524 Warsaw, Poland

Bibliografia

• [1] A. R. Hard, “Preliminary test of spot weld shunting in 24ST Alclad”, Welding Journal 27 (6), 491-495 (1948).
• [2] H. S. Chang and H. S. Cho, “A Study on the Shunt Effect in Resistance Spot Welding”, Welding Journal 69, 308-316 (1990).
• [3] P. Howe, “Spot weld spacing effect on weld button size”, Sheet Metal Welding Conference VI, AWS Detroit Section, Paper C03, (1994).
• [4] B. Wang, M. Lou, Q. Shen, Y. B. Li and H. Zhang, “Shunting effect in resistance spot welding steels - part 1: experimental study”, Welding Journal 92 (6), 182s-189s (2013).
• [5] J. Senkara and H. Zhang, “Cracking in spot welding aluminum alloy AA5754”, Welding Journal 79, 194s-201s (2000).
• [6] H. Zhang, J. Senkara and X. Wu, “Suppressing cracking in resistance welding AA5754 by mechanical means”, Journal of Manufacturing Science and Engineering 129, 194s-201s (2002).
• [7] Y. B. Li, B. Wang, Q. Shen, M. Lou and H. Zhang, “Shunting effect in resistance spot welding steels - part 2: theoretical analysis”, Welding Journal 92, 231s- 238s (2013).
• [8] H. Huh and W.J. Kang, “Electro-thermal analysis of electrode resistance spot welding process by a 3-D finite element method”, Journal of Materials Processing Technology 63, 672- 677 (1997).
• [9] N. Ma and H. Murakawa, “Numerical and experimental study on nugget formation in resistance spot welding for three pieces of high strength steel sheets”, Journal of Materials Processing Technology 210, 2045-2052 (2010).
• [10] J.A. Greenwood, “Temperature in spot welding”, British Welding Journal 8 (6), 316-322 (1961).
• [11] C.L. Tsai, O.A. Jammal, J.C. Papritan and D.W. Dickinson, “Analysis and development of a real time control methodology in resistance spot welding”, Welding Journal 70 (12), 339s-351s (1992).
• [12] T. Loulou, P. Masson and P. Rogeon, “Thermal characterization of resistance spot welding”, Numerical Heat Transfer Part B: Fundamentals 49 (6), 559-584 (2006).
• [13] J. Shen, Y. Zhang, X. Lai and P.C. Wang, “Modeling of resistance spot welding of multiple stacks of steel sheets”, Materials and Design 32, 550-560 (2011).
• [14] A. Nied, "The finite element modeling of resistance spot welding process", Welding Journal 63 (4), 123-132 (1984).
• [15] J. E. Gould, “An examination of nugget development during spot welding, using both experimental and analytical techniques”, Welding Journal, 1s- 10s (1987).
• [16] W. Zhang, “Design and implementation of software for resistance welding process simulations”, Journal of Material and Manufacture 112 (5), 556-564 (2003).
• [17] J.H. Kim, Y. Cho and Y.H. Jang, “Estimation of the weldability of single-sided resistance spot welding”, Journal of Manufacturing Systems 32, 505-512 (2013).
• [18] M. Hamedi, H. Eisazadeh and M. Esmailzadeh, “Numerical simulation of tensile strength of upset welded joints with experimental verification”, Material & Design 31, 2296-2304 (2010).
• [19] X. Sun and P. Dong, “Analysis of Aluminum Resistance Spot Welding Processes Using Coupled Finite Element Procedures”, Welding Research, 215S-221S (2000).
• [20] COMSOL AB (2013). COMSOL Multiphysics - Heat Transfer Module Model Library Manual, Ver. 4.4, COMSOL AB ltd.
• [21] H. Zhang and J. Senkara, Resistance welding: fundamentals and applications, CRC Press, UK (2006).
• [22] Z. Hou, I. Kim, Y. Wang and C. Li, C. Chen, “Finite element analysis for the mechanical features of resistance spot welding process”, Journal of Materials Processing Technology 185, 160-165 (2007).
• [23] J. Sessler and V. Weiss, Materials data handbook - aluminum alloy 2219, 2nd ed., Western Applied Research & Development, CA (1966).
• [24] E. L. Rooy, R.B.C. Cayless and J.W. Bray, ASM handbook: properties & selection - nonferrous alloys and special-purpose materials, 10th ed., Vol. 2, 3-165 (1990).
• [25] MIL-HDBK-5H: Metallic materials and elements for aerospace vehicle structures, Chapter 3, 164-192, Department of Defense, USA (1998).
• [26] M. Vogler and S. Sheppard, “Electrical contact resistance under high loads and elevated temperature”, Welding Journal 72 (6), 231s-238s (1993).
• [27] M. Jafari Vardanjani, M. Ghayour and R. Mokhtari Homami, “Analysis of the vibrational stress relief for reducing the residual stresses caused by machining”, Experimental Techniques 6 (38), 1- 9 (2014).
• [28] Military Specification-Welding-Resistance: Spot And Seam, MlLW-6858D, Department of the Air Force, USA (1978).
• [29] W.H. Kearns, Metals and Their Weldability, 7th ed., Vol. 4, American Welding Society Inc, FL, (1997).
• [30] K. R. Chan, “Weldability and degradation study of coated electrodes for resistance spot welding”, M.Sc. Thesis, University of Waterloo, Canada (2005).
• [31] J. Saleem, A. Majid, K. Bertilsson, T. Carlberg and N. Ul Islam, “Nugget formation during resistance spot welding using finite element model”, World Academy of Science - Engineering and Technology 67, 588- 593 (2012).
• [32] Procedure for spot welding of uncoated and coated low carbon and high strength steels, Section 6, Document No. III-1005-93, International Institute of Welding.

Uwagi

PL

Opracowanie ze środków MNiSW w ramach umowy 812/P-DUN/2016 na działalność upowszechniającą naukę.