Analysis of resistance welding processes and expulsion of liquid metal from the weld nugget

• Autorzy: Mikno Z. , Pilarczyk A. , Korzeniowski M. , Kustroń P. , Ambroziak A.

Identyfikatory

DOI

10.1016/j.acme.2017.08.003

• Języki publikacji: EN

Abstrakty

EN

The article presents the process of resistance welding in relation to the expulsion of liquid metal from the weld nugget. The research-related tests involved the synchronic recording of welding process parameters such as welding current and voltage as well as electrode force and travel. The phenomenon of expulsion was filmed using a high speed camera. The tests aimed to determine the most effective parameter as regards the detection of expulsion as well as the accurate determination of the moment of expulsion in relation to the above-named parameter. During the tests it appeared that the most favourable parameter was the force of electrodes. The tests required the precise synchronisation of the recording of process parameters with the recording of images (using the camera). The uncertainty of expulsion time determination was estimated at 0.1 ms. The research-related experimental tests were focused on the possibility of eliminating expulsion by stopping (blocking) the flow of welding current. In the case of expulsion, the process of welding was continued with a delayed second current pulse. The force signal, on the basis of which the expulsion detection was performed, was analysed using a dedicated controller which implementing the algorithm of discreet differentiation. The tests were performed using an inverter welding machine having an internal transformation frequency of 10 kHz. In this study, SORPAS software-aided FEM analysis was performed to analyse the possibility of the effective reduction of the expulsion phenomenon.

Słowa kluczowe

EN

expulsion from welding nugget; resistance spot welding; resistance spot welding process controller

PL

spawanie; zgrzewanie oporowe; spawarka inwertorowa

• Wydawca: Springer ; Wrocław University of Science and Technology
• Czasopismo: Archives of Civil and Mechanical Engineering
• Rocznik: 2018
• Tom: Vol. 18, no. 2
• Strony: 522--531
• Opis fizyczny: Bibliogr. 16 poz., rys., tab., wykr.

Twórcy

autor

Mikno Z.

• Welding Institute, Gliwice, Poland

autor

Pilarczyk A.

• Welding Institute, Gliwice, Poland

autor

Korzeniowski M.

• Wroclaw University of Technology in Poland, Mechanical Department, Department of Materials Science, Welding and Strength of Materials, Poland

autor

Kustroń P.

• Wroclaw University of Technology in Poland, Mechanical Department, Department of Materials Science, Welding and Strength of Materials, Poland

autor

Ambroziak A.

• Wroclaw University of Technology in Poland, Mechanical Department, Department of Materials Science, Welding and Strength of Materials, Poland

Bibliografia

• [1] H. Zhang, J. Senkara, Resistance Spot Welding, Fundamentals and Applications, 2nd ed., CRC Press, Taylor & Francis Group, 2011.
• [2] J. Senkara, H. Zhang, Mechanism of Expulsion of Liquid Metal During Resistance Spot Welding, Welding Technology Review, No. 5-7, 2004.
• [3] Z. Mikno, A. Pilarczyk, Sz. Kowieski, A. Ambroziak, M. Korzeniowski, P. Kustroń. Sposób i zgrzewarka inwertorowa do zgrzewania rezystancyjnego, zwłaszcza punktowego w warunkach ekspulsji (Method and inverter resistance welding machine, mainly dedicated for spot welding in expulsion conditions), Patent P. 416596 Polish Patent Office.
• [4] J. Senkara, H. Zhang, S.J. Hu, Expulsion prediction in resistance spot welding, Weld. J. 123-S (April) (2004) https:// app.aws.org/wj/supplement/wj0404-123.pdf.
• [5] H. Zhang, et al., Expulsion modeling in RSW of steel and Al alloys, in: AWS Sheet Metal Conf. VIII, 1998.
• [6] Research Project No. PBS3/B4/12/2015: Development of Innovative High-Efficient Compact Resistance Welding Machine of Higher Frequency. Realisation 2015–2017, 2017.
• [7] A. Pilarczyk, Lecture and publication: visual recording of the welding arc with simultaneous recording of current–voltageparameters of MIG/MAG welding process, XVI, in: Scientific Welding Conference 25–27.05.2010, Międzyzdroje, Poland, 2010.
• [8] Research Project No. Da-105/2, Research into the Possibility of Visual Recording of Welding Arc Synchronised with the Recording of Welding Process Parameters. Realisation 2009– 2010, 2010.
• [9] Z. Mikno, Z. Bartnik, Heating of electrodes during spot resistance welding in FEM calculations, Arch. Civ. Mech. Eng. 16 (1) (2016) 86–100.
• [10] A. Ambroziak, R. Maev, M. Korzeniowski, P. Kustroń, A. Chertov, Ultradźwiękowa kontrola zgrzein punktowych złączy stalowych w czasie rzeczywistym,(Ultrasonic quality control of spot welds of steel joints in the real time, in Polish), Biul. Inst. Spaw. Gliw. R. 52 (5) (2008) 152, 155–158.
• [11] M. Pouranvari, A. Abedi, P. Marashi, M. Goodarzi, Effect of expulsion on peak load and energy absorption of low carbon steel resistance spot welds, Sci. Technol. Weld. Join. 13 (1) (2008).
• [12] Cold-Rolled DP800-UC, 2017 www.tatasteeleurope.com (accessed: 30.06.17).
• [13] A. Ambroziak, A. Tobota, K. Tokarz, P. Kustroń, Testing of thin-walled steel joints fabricated by spot welding and plug welding, Weld. Int. 25 (4) (2011) 277–282.
• [14] M. Korzeniowski, B. Białobrzeska, P. Kustroń, E. Harapińska, Zastosowanie mikroskopii akustycznej do oceny niezgodności połączeń zgrzewanych punktowo,(Application of scanning acoustic microscopy for quality evaluation of spot welds), Prz. Spaw. R. 87 (12) (2015) 92–94.
• [15] A. Ambroziak, M. Korzeniowski, P. Kustroń, M. Winnicki, P. Sokołowski, E. Harapińska, Friction welding of aluminium and aluminium alloys with steel, Adv. Mater. Sci. Eng. 2014 (2014) 1–15.
• [16] A. Ambroziak, M. Korzeniowski, P. Kustroń, M. Winnicki, Friction welding of niobium and tungsten pseudoalloy joints, Int. J. Refract. Met. Hard Mater. 29 (4) (2011) 499–504.

Uwagi

PL

Opracowanie rekordu w ramach umowy 509/P-DUN/2018 ze środków MNiSW przeznaczonych na działalność upowszechniającą naukę (2018)