• Journal of Welding and Joining
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• v.12 no.2
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• pp.76-86
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• 1994

Spot welding behavior of galvanized steel has been studied using both numerical and experimental techniques. The model that used to calculate temperature distribution within weldment is two-dimensional axis-symmetric finite difference method, and nugget sizes of specimen welded in condition of welding current and time has been estimated by experiment Results have shown that nugget sizes are increased in proportion to welding current and time, but the growth rate of nugget is decreased. Shear-tensile strength tests have shown interface fracture when welding current is 7, 9KA, welding time is 8-14cycle and 11KA, 8-10cycle respectively, but above 7, 9KA fracture shows button type. In button fracture, shear-tensile strengths have been proportional to nugget sizes.

• Journal of Welding and Joining
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• v.20 no.1
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• pp.55-61
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• 2002

The automobile is made up of about twenty thousand parts. Some parts are formed by pressing and combined by spot welding. Among them, steel palate of fuel tank is formed in the metal mold and bending parts are jointed by spot and seam welding. To find weldability conditions of spot welding, clearance between two welding steel plates was made and after spot welding, weldability is evaluated by means of tensile shear load, nugget size and shape. Specimen used in this study was a mild steel of 1.2mm thickness and electrode was Cu-Cr alloy of 6mm diameter. When spot welding started, the clearance of two steel plates was changed 0mm, 3mm and 5mm step by step. The fractured surface of specimen after this test was observed by Optical Microscope to measure microstructure and nugget shape. When clearance of two specimen was 3mm and 5mm, strength and nugget size was decreased and nugget shape was not clear.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2004.10a
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• pp.49-53
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• 2004

Thin spot welding is frequently used for industrial purpose, such as automobile and aerospace industries and household appliances due to its high performance. In these days, the systemization of welding process made it possible to produce more precise or smaller electric parts. And when it comes to welding of steel sheets, the size of nugget must be getting smaller. Therefore, welding conditions are limited to avoid defects, such as deformation, damage and weakening of joining area. In this research, thin spot welding establishes the welding conditions, and then the measurement of the nugget size by the nondestructive inspection has been conducted. As a result, the right estimation of the nugget size, the detection of corona bond near joining area, the selection of the optimum ultrasonic mode, and setup for ultrasonic inspection are studied. From the trustworthy solutions of the nugget size estimated by results of measurement, the optimum inspection conditions depending upon the width of welding parts are determined as well.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2003.10a
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• pp.301-306
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• 2003

Spot welding is frequently used for industrial purpose, such as automobile and aerospace industries and household appliances due to its high performance. In these day, robotization and systemization of welding process made it possible to produce more precise or smaller electric parts. And when it comes to welding of steel sheet, the size of nugget must be getting smaller. Therefore, welding conditions are limited to avoid defects, such as deformation, damage, weakening of joining area. In this research, the measurement of the nugget size by the nondestructive inspection has been conducted. As a result, the right estimation of the nugget size and void defects, the detection of corona bond near joining area, the selection of the optimum ultrasonic mode, and set up for ultrasonic inspection are studied. From the trustworthy solutions of nugget size estimated by results of measurement, the optimum inspection conditions depending upon the width of welding parts are determined as well.

• Transactions of the Korean Society of Machine Tool Engineers
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• v.14 no.5
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• pp.74-79
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• 2005

Spot welding widely used in automotive and aerospace industries has made it possible to produce more precise and smaller electric part by robotization and systemization of welding process. The quality of welding depends upon the size of nugget between the overlapped steel plates. Recently, the thickness of the steel plates becomes much thinner and hence, it introduces the smaller size of nugget. Therefore, it is necessary to develop the criterion to evaluate the quality of weld in order to obtain the optimal welding conditions for the better performance. In this paper, a thin steel plates, 0.1mm through 0.3mm thickness, have been spot-welded at different welding conditions and the nugget sizes are examined by defocused scanning microscopy. The relationships between nugget sizes and weldability have been investigated experimentally. The result of ultrasonic technique shows the good agreement with that of the tensile test.

• Journal of Welding and Joining
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• v.18 no.2
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• pp.184-184
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• 2000

In this study, the lap welding between austenitic stainless steel and carbon steel was carried out using arc spot welding process and weldability of welded specimens was estimated. From the tensile-shear strength test, micro Vickers hardness test, and microstructure observation, specimen of 6.5mm(hole of upper plate) showed the best results in terms of tensile-shear strength and nugget shape. And there was an unmixed zone in fusion boundary between the carbon steel base metal and bulk weld metal. This zone had very thin width with the hard microstructure. The shape of weld nugget in arc spot welding of dissimilar metal welds was predicted by searching thermal history of a weld joint through a three-dimensional finite element model. From the numerical analysis, predicted the shape of weld nugget showed good agreement with the experiment(Received August 24, 1999)

• Journal of Welding and Joining
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• v.18 no.2
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• pp.57-63
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• 2000

In this study, the lap welding between austenitic stainless steel and carbon steel was carried out using arc spot welding process and weldability of welded specimens was estimated. From the tensile-shear strength test, micro Vickers harness test, and microstructure observation, specimen of $psi6.5mm$(hole of upper plate) showed the best results in terms of tensile-shear strength and nugget shape. And there was an unmix zone in fusion boundary between the carbon steel base metal and bulk weld metal. This zone had very width with the hard microstructure. The shape of weld nugget in arc spot welding of dissimilar metal melds was predicted by searching thermal history of a weld joint through a three-dimensional finite element model. From the numerical analysis, predicted the shape of weld nugget showed good agreement with the experiment.

• 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.

• Proceedings of the KWS Conference
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• 1992.10a
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• pp.91-95
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• 1992

The resistance spot welding process has been extensively used for joining of sheet metals, which are subject to variation of many process variables. Many qualitive analyses of sampled process variables have been attempted to predict nugget size. In this paper, dynamic resistance and electrode movement signal which is a good indicative of the nugget size was examined by introducing an artificial neural network estimator. An artificial neural feedforward network with back-propagation of error was applied for the estimation of the nugget size. The prediction by the neural network is in good agreement with the actual nugget size for resistance spot welding of galvanized steel. The results are quite promising in that the quantitative estimation of the invisible nugget size can be achieved without conventional destructive testing of welds.

• Journal of the Korean Society for Nondestructive Testing
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• v.25 no.3
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• pp.209-214
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• 2005

Spot welding is the most widely used in automotive and aerospace industries. The quality of weld depends upon the size of nugget between the overlapped steel plates. Recently, the thickness of the steel plates is much thinner and hence, it introduces the smaller size of nugget. Therefore, it is necessary not only to develop the criterion to evaluate the quality of weld but also to obtain the optimal welding conditions for the better performance. In this paper, the steel plates, 0.5 mm through 1.5 mm thickness, have been spot welded at different welding conditions and the nugget sizes are examined by ultrasonic technique (C-scan type). The relationships between the nugget sizes and the weldability have been investigated. The result of ultrasonic technique shows the good agreement with that of the tensile test.