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Resistance spot welding of aluminium alloy sheet 5J32 using SCR type and inverter type power supplies

Kim D., Park H., Hwang I., Kang M.

Archives of Materials Science and Engineering

2009

Vol. 38, nr 1

55-59

Purpose: A characteristic was compared and analyzed between the lobe diagram of SCR type resistance spot welding and that of inverter type resistance spot welding of the aluminum alloy sheet 5J32 for the car body. Design/methodology/approach: Using the lobe diagram on the electrode force, weld time, and weld current which are process variables of the resistance spot welding, the range of optimal welding condition was determined. The low limit of the range of the optimal welding condition was decided by the lower limit of the tensile strength of the aluminum alloy sheet 5J32, and the upper limit was decided by whether an expulsion occurs or not. Findings: It was found that the range of the optimal welding condition of the inverter type resistance spot welding was larger than the SCR type resistance welding and that the nugget size of inverter type resistance spot welding was larger in the same welding condition. Research limitations/implications: A comparison was between the lobe diagram at the SCR type on the aluminum alloy sheet 5J32 and the lobe diagram at the inverter type resistance spot welding. Practical implications: In this study, by comparing the range of the appropriate welding condition of the resistance spot welding between SCR type and inverter type power supplies, the characteristic of the appropriate welding range by the power supply characteristic could be confirmed. Originality/value: This study compared the characteristic of the resistance spot welding between the SCR type and inverter type power supply using lobe diagram. It was confirmed that the range of appropriate welding conditions of the inverter type resistance spot welding was large.

Optimisation of the wire feed rate during pulse MIG welding of Al sheets

Park H. J., Kim D. C., Kang M. J., Rhee S.

Journal of Achievements in Materials and Manufacturing Engineering

2008

Vol. 27, nr 1

83-86

Purpose: This paper aims at optimizing the wire feed speed against the welding speed during the pulse-MIG (Metal Inert Gas) lap joint fillet weld of 1.6 mm aluminium alloy typically used for the light-weight car body. Design/methodology/approach: Welding experiments were conducted with various wire feed speeds of 0.5 m/min, 1.0 m/min, and 1.5 m/min, and the bead characteristics were evaluated. As shape factors of the weld bead, the bead width, back bead width, and bead cross-section area were measured. According to the weld quality and defined objective functions, the wire feed speed was optimized for various welding speeds. Findings: The wire feed speed that induces the optimum weld quality was found with welding speeds of 0.5 m/min, 1.0 m/min, and 1.5 m/min. The optimum lap welding conditions were then suggested for 1.6 mm aluminium alloy considering the productivity and quality. Research limitations/implications: The optimization will be extended to various aluminium alloys and the optimized results will be stored in the Al welding database of the intelligent welding power source development. Practical implications: With the increase of the welding speed for aluminium sheet welding, the corresponding wire feed speed should increase as well. On the other hand, it is clear that the maximum value of the objective function has decreased. Originality/value: This research revealed the relationship between the welding speed and the wire feed speed considering the welding productivity and quality. In addition, the criterion to evaluate the degree of weldability during lap welding is suggested according to the quality and objective functions.