• 대한용접접합학회:학술대회논문집
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• 대한용접접합학회 2003년도 춘계학술발표대회 개요집
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• pp.99-101
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• 2003

This study deals with the resistance spot welding of aluminized steels. According to the test results it was clear that the weldability of aluminized steels was equivalent to or better than that of Zn coated steel. Microstructural inspection revealed that molten aluminum that was repelled from the weld during the process, piled up at the split zone. The test results also demonstrated that the weld metal of aluminized steels could hardly produce the weld crack even higher welding heat Input was applied.

• Journal of Welding and Joining
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• 제32권6호
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• pp.1-7
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• 2014

For the resistance spot welds of CR1180 and GA1180 TRIP steels, the weld quality evaluation method using the digitalized X-ray transmission imaging apparatus was investigated in comparison with the crosssectional examination method. In the case of the resistance spot welding of CR1180, three circular regions, such as WZ(white zone), GZ(grey zone) and DZ(dark zone), appeared on X-ray image and they corresponded to the diameters of indentation mark, nugget and corona bond, respectively. The variation of X-ray transmission thickness due to the thickness variation of the weld seemed to be mainly responsible for the formation of those contrasts. The X-ray image contrast formed from the variation of transmission thickness at the outer border line of DZ could also enable the inspections of the notch shape, nonuniformity of the welding pressure and spatter from its sharpness, concentricity and the normal straight line, respectively. The X-ray image of the resistance spot weld of galvannealed GA1180 TRIP steel was very similar to that of CR1180 TRIP steel except the crown shaped outer border line of DZ which was considered to be due to the melting behavior of zinc having the boiling temperature even lower than the melting temperature of steel.

• Journal of Welding and Joining
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• 제26권5호
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• pp.79-89
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• 2008

With the increased use of surface textured steel sheet in body-in-white assembly, resistance spot weldability of these steels is considered to be an important subject. This study evaluated nugget formation and weldability by measuring dynamic resistance with various weld pressure, current, and weld time for steel sheet with two different surface roughnesses. The surface roughness for T-H steel ($R_{a}=1.70\;{\mu}m$) was higher than that for T-L steel ($R_{a}=1.33\;{\mu}m$), and resulted in increased contact resistance and heating for T-H steel spot welding. Therefore, at low weld current and weld cycle ranges, the T-H steel showed better weldability over the T-L steel. The evaluations of weld interface showed that the fusion zone in the T-H steel sheet was continuous in contrast to discontinuous fusion zone for T-L steel sheet at the same welding conditions. A comparison of dynamic resistance and tensile-shear strength (TSS) between T-H and T-L steel sheet suggested that high surface roughness provided larger heating at early cycle of welding and larger TSS.

• 한국자동차공학회논문집
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• 제6권6호
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• pp.40-52
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• 1998

A good grasp of the failure mechanisms of resistance spot weld, widely used in joining the auto-panels, in essential to the structural/crashworthy analyses and integrity assessment of the whole auto-body. In this study, We provide an estimative model describing the failure behavior of resistance spotf weld, and apply the model to the finite element analysis of crashworthiness. First, in "Part 1-Failure Criteria", to be used for the finite element analysis of spot-welded structural panels of an auto-body, (i) a methodology for quantifying the spot weld failure and the accompanying failure criteria are presented, and (ii) the coefficients of the failure equation are determined by a munimum number of appropriate experimental tests. To achieve these, we derive the functional form of the failure envelop by limit analysis, and correlate it with the form in PAM-$CRASH^{TM}$ code, and also investigate the effect of the failure coefficients on the failure envelop form. An estimative model obtained in this Part1, as spot weld failure criteria is applied to the Macroscopic finite element analysis of autobody structural panels using PAM-$CRASH^{TM}$ code in Part 2.

• Journal of Welding and Joining
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• 제33권6호
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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.

• 전기학회논문지
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• 제64권11호
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• pp.1571-1577
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• 2015

A new mixed mode control of constant power and constant current for resistance spot welding inverter is proposed to improve the weld quality. The conventional control scheme adopts constant current or constant power control mode, however, it is not easy to guarantee the high weld quality because of the nonlinear resistance characteristics of the welding point. The proposed method utilizes the nonlinear characteristics by measuring the dynamic resistance in real time. Therefore, it is possible for the welder to be controlled adaptively depending on the welding state. Experimental results show that the proposed control scheme improves the weld quality by 6.8 times compared with the conventional constant current mode control.

• International Journal of Automotive Technology
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• 제7권5호
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• pp.579-584
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• 2006

Aluminum Resistance Spot Weld(Al RSW) is an enabling technology for body assembly of low mass fraction vehicles. Due to the unreliable durability of spot-welded joints, applications of Al RSW are limited. This study presents experimental investigation on the use of a post-weld cold working process to improve the fatigue strength of Al RSW. The post-weld cold working process includes special shaped indenters that are pressed or driven into the structure to induce compressive residual stresses. The mechanical properties of the post-weld cold worked Al RSW were investigated, including the experimental results of fatigue and micro-hardness tests. Comparisons of the mechanical properties and qualitative results between the as-welded RSW specimens and the post-weld cold worked RSW specimens are discussed. The post-weld cold worked Al RSW samples had an increase in both microhardness and fatigue life.

• Journal of Welding and Joining
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• 제15권4호
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• pp.42-62
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• 1997

Resistance spot welding has been widely used in the sheet metal joining processes because of its high productivity and convenience. Recently, automobile industries are trying to replace partly steel sheets with aluminum alloy sheets. Among currently produced aluminum alloys, Al alloy sheets of Al-Mg-Si(6000 series) are being tested. Especially, 6000 series are the most probable substitute in view of strength and weldability. In this paper, an attempt was made to apply resistance spot welding to joining of dissimilar sheet metals (KS6383+SCPZn or KS6383+SHCP). An effort was made to balance heating rate in the Al alloy with that in the steel sheets by increasing electrode tip diameter. Although resistance spot welding of Al alloy sheet and sheet metals does not produce desirable nugget, it proved to have reasonable strength if optimal weld condition is found by tensile-shear strength and fatigue life test. Since spot weld joints in automobile are always experiencing repeated load, spot welding methodology proposed in this paper is found to be not suitable to automobile body manufacturing.

• Journal of Welding and Joining
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• 제17권2호
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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.

• 대한기계학회논문집
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• 제17권2호
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• pp.393-406
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• 1993

In resistance spot welding process, size of molten nuggest have been utilized to assess the integrity of the weld quality. However real-time monitoring of the nugget size is an extremely difficult problem. This paper describes the design of an artificial neural networks(ANN) estimator to predict the nugget size for on-line use of weld quality monitoring. The main task of the ANN estimator is to realize the mapping characteristics from the sampled dynamic resistance signal to the actual negget size through training. The structure of the ANN estimator including the number of hidden layers and nodes in a layer is determined by an estimation error analysis. A series of welding experiments are performed to assess the performance of the ANN estimator. The results are quite promissing in that real-time estimation of the invisible nugget size can be achieved by analyzing the dynamic resistance signal without any conventional destructive testing of welds.