• Proceedings of the KWS Conference
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• 2002.10a
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• pp.330-335
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• 2002

Resistance spot welding is one of the most widely used processes in sheet metal fabrication. Quality assurance of welding has been important to increase the productivity. In this study, weld quality estimation using primary circuit dynamic resistance applied to the in-process real-time systems. For quality estimation, factors relating to quality were extracted from the dynamic resistance, measured in the timer. The relationship between these factors and weld quality was determined through a artificial neural network model. This method has the advantage over the conventional one, such as obtaining the quality information without the use of extra devices.

• Journal of Welding and Joining
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• v.18 no.2
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• pp.239-239
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• 2000

Automobile manufacturers have employed resistance spot welding(RSW) to join steel sheets for structural rigidity o automobile body. Driven by the need to reduce weight and fuel consumption, car companies have been evaluating aluminum intensive vehicles(AIVs) as a way to reduce vehicle weight without downsizing. During the transition from all steel-construction vehicle body to aluminum intensive body, joining aluminum to steel sheets emerges as a serious contender in automobile body. This paper deals with application of transition material to RSW aluminum to steel. Placing transition material insert between the aluminum/steel interface was found very effective to overcome incompatibility between aluminum and steel. Use of transition insert allows for two separate weld muggets to be formed in their respective aluminum/ aluminum and steel/ steel interfaces. This RSW process was monitored with the aid of dynamic resistance sampling. Typical patterns in sampled dynamic resistance curves indicated formation of sound nugget. (Received February 28, 2000)

• Journal of Welding and Joining
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• v.18 no.2
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• pp.112-118
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• 2000

Automobile manufacturers have employed resistance spot welding(RSW) to join steel sheets for structural rigidity of automobile body. Driven by the need to reduce weight and fuel consumption, car companies have been evaluating aluminum intensive vehicles(AIVs) as a way to reduce vehicle weight without downsizing. During the transition from all steel-construction vehicle body to aluminum intensive body, joining aluminum to steel sheets emerges as a serious contender in automobile body. This paper deals with application of transition material to RSW aluminum to steel. Placing transition material insert between the aluminum/steel interface was found very effective to overcome incompatibility between aluminum and steel. Use of transition insert allows for two separate weld nuggets to be formal in their respective aluminum/aluminum and steel/steel interfaces. This RSW process was monitored with the aid of dynamic resistance sampling. Typical patterns in sampled dynamic resistance curves indicated formation of sound nugget.

• Journal of the Korean Society for Precision Engineering
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• v.16 no.10
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• pp.141-151
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• 1999

The resistance Spot Welding is widely used in the field of assembling the plates. However we don't still have any satisfactory solution, which is non-destructive quality evaluation in real-time or on-line, against it. Moreover, even though the rate of welding under the condition of expulsion has been high until now, quality control of welding against expulsion hasn't still been established. In this paper, it was proposed on the quality assurance technique of resistance spot welding pieces using Neuro-Fuzzy algorithm. Four parameters from electrode separation signal in the case of non-expulsion, and dynamic resistance patterns in the case of expulsion are selected as fuzzy input parameters. The parameters consist of Fuzzy Inference System are determined through Neuro-Learning algorithm. And then, fuzzy Inference System is constructed. It was confirmed that the fuzzy inference values of strength have within ${\pm}$4% error specimen in comparison with real strength for the total strength range, and the specimen percent having within ${\pm}$1% error was 88.8%. According to KS(Korean Industrial Standard), tensile-shear strength limit for electric coated of zinc is 400kgf/mm2. Judging to the quality of welding is good or bad, according to this criterion and the results of inference, the probability of misjudgement that good quality is valuated into poor one was 0.43%, on contrary it was 2.59%. Finally, the proposed Neuro-Fuzzy Inference System can infer the tensile-shear strength of resistance spot welding pieces with high performance for all cases-non-expulsion and expulsion. And On-Line Welding Quality Inspection System will be realized sooner or later.

• Journal of Welding and Joining
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• v.17 no.2
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• pp.97-103
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• 1999

The dynamic resistance monitoring in primary circuit is one of the important issues. Because in-process and real time quality assurance of resistance spot weld is needed to increase the product reliability. In this study, new dynamic resistance detecting method is proposed as a practical manner of weld quality assurance using instantaneous current and voltage measured at the primary circuit. and also, various patterns of primary dynamic resistance curve are characterized with the macro photograph and the weldability lobe curve. It is found that the primary dynamic resistance patterns are basically similar to those of the secondary, but there is evident advantage such as no extra devices are needed to obtain the quality information and eventually real time feedback control will be possible.

• Journal of Welding and Joining
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• v.27 no.6
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• pp.36-42
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• 2009

In the present day, new performances are demanded for automobile body steel sheet for example, light weight, durability, resistance corrosion and environmental protection. For an improvement of resistance corrosion, European automobile companies developed pre-sealed steel in 1990's. Pre-sealed steel have organic coated layer upper zinc coated layer. Evaluating a resistance spot weldability of pre-sealed steel plate is important because resistance spot welding is used mainly in automobile body joining process. In this study, evaluating a weldability of pre-sealed steel plate was carried out using lobe diagram, dynamic resistance and high-speed image. Usually, Pre-sealed steel has poor weldability than GA steel's. To improve a weldability of pre-sealed steel sheet, pre-current was applied to welding process. Pre-current is applied prior to base-current. In conclusion, the weldability of pre-sealed steel has been improved than GA steel's by applying pre-current.

• Journal of Welding and Joining
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• v.33 no.6
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• pp.13-20
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• 2015

Many automotive companies are endeavoring to improve the quality of resistance spot welding by updating body-in-white (BIW) production line with adaptive control spot welding system to compensate the process disturbances such as gap, electrode wear, oxidized surfaces, poor fit up and adhesive etc. Most of the commercial adaptive weld controllers require proper "Initial Welding Schedule" or "Reference weld" to achieve compensation in welding parameters during real time welding. In this study, the compensation of a commercial adaptive weld controller had been observed and analyzed thoroughly for various process disturbances to find optimal initial welding schedule. It was observed that 90 percent of the expulsion current in constant current control as reference welding schedule conferred the maximum button diameter in adaptive control welding. Finally, effects of each disturbance in combined field disturbances system with adaptive control had also been confirmed with the design of experiment (DOE) by minitab(R)16 for combined disturbances situation and suitability of optimum initial weld current had also established with real body part validation test.

• Journal of Welding and Joining
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• v.20 no.2
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• pp.59-64
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• 2002

When the vehicle travels in an actual road, resistance spot weldments of the vehicle structure are exposed to complex loading state. Since the fatigue strength in resistance spot weldment of vehicle body can be determined by effect of residual stresses and loading state of driving, estimating actual loading state and considering residual stress effect are needed. In this study, Fatigue stress-fatigue life relation concerned residual stress effect was obtained by thermo elastic plastic finite element analysis. And applied loading in resistance spot weldments of vehicle body was calculated by dynamic analysis. Presumption of fatigue life was performed using proposed method

• Journal of Welding and Joining
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• v.29 no.5
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• pp.72-81
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• 2011

In the present day, the needs of new steel for lightweight car-body have been increased in the automotive industry. however, the resistance spot welding is difficult to apply to the new steel because of the narrow weld current range and defects. As the solutions to these problems, adhesive bonding process is proposed. Adhesive bonding which reduce noise and vibration can be applied to joining the new steel. In this study, crash tests of b-pillar applied the resistance spot welding, structural adhesive bonding, the mixture of the structural adhesives and resistance spot welding were performed. And FEM crash model for b-pillar applied the structural adhesive bonding was developed. The results of experiment and analysis on b-pillar crash test were compared to verify the validity.

• Steel and Composite Structures
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• v.18 no.2
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• pp.345-355
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• 2015

In this study, the effects of weld parameters on nugget size and tensile-shear strength of welding joint in electrical resistance spot welding of galvanized DP 600 steel sheets having 1.2 mm were investigated. Taguchi design method has been employed to examine the effects of five parameters of welding current, electrode pressure, welding time, clamping time and holding time by using the $L_{27}(5^3)$ orthogonal array. Results showed that the most effective parameters on tensile shear strength and the nugget size ratio (hn/dn) were found as welding current and welding time, whereas electrode pressure, clamping time and holding time were less effective factors. Max. 545 MPa strength was obtained through proposed optimum conditions by Taguchi technique.