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

Vardanjani M. J., Araee A., Senkara J., Jakubowski J., Godek J.

Bulletin of the Polish Academy of Sciences. Technical Sciences

2016

Vol. 64, nr 2

425--434

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.

On the failure mode of resistance spot welded HSLA 420 steel

Pouranvari M.

Archives of Metallurgy and Materials

2013

Vol. 58, iss. 1

67-72

Failure mode of resistance spot welds (interfacial vs. pullout) is a qualitative measure of resistance spot weld performance. Considering adverse effect of interfacial failure mode on the vehicle crashworthiness, process parameters should be adjusted so that the pullout failure mode is guaranteed ensuring reliability of spot welds during vehicle lifetime. In this paper, metallurgical and mechanical properties of HSLA 420 resistance spot welds are studied with particular attention to the failure mode. Results showed that the conventional weld size recommendation of 4t0:5 (t is sheet thickness) is not sufficient to guarantee pullout failure mode for HSLA steel spot welds during the tensile-shear test. Considering the failure mechanism of spot welds during the tensileshear test, minimum required fusion zone size to ensure the pullout failure mode was estimated using an analytical model. Fusion zone size proved to be the most important controlling factor for peak load and energy absorption of HSLA 420 resistance spot weld.

Tryb uszkodzenia zgrzein (pękanie na granicy faz a wyrywanie) jest jakościowa miara zachowania zgrzein. Biorąc pod uwagę niekorzystny wpływ uszkodzenia na granicy faz na odporność pojazdu na uderzenia, parametry zgrzewania powinny być ustawione tak, ze trybem uszkodzenia jest wyrywanie co gwarantuje niezawodność zgrzein w czasie eksploatacji pojazdu. W pracy, badane sa metalurgiczne i mechaniczne właściwości zgrzein stali HSLA 420 ze szczególnym uwzględnieniem trybu uszkodzenia. Wyniki próby rozciągania i ścinania wykazały, ze konwencjonalne zalecenie rozmiaru spoiny 4t0:5 (t - grubość) nie jest wystarczające, aby zapewnić ze trybem uszkodzenia jest wyrywanie. Biorąc pod uwagę mechanizm uszkodzenia zgrzein w czasie próby rozciągania i ścinania, minimalna wielkość strefy stopionej wymagana do zapewnienia, ze trybem uszkodzenia jest najbardziej istotnym czynnikiem decydującym o maksymalnym obciążeniu i pochłanianiu energii przez zgrzewana stal HSLA 420.