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Title: IR-based Spot Weld NDT in Automotive Applications

 [1];  [1]
  1. ORNL
Publication Date:
Research Org.:
Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
Sponsoring Org.:
USDOE Office of Energy Efficiency and Renewable Energy (EERE)
OSTI Identifier:
DOE Contract Number:
Resource Type:
Resource Relation:
Conference: Thermosense XXXVII - 2015, Baltimore, MD, USA, 20150420, 20150424
Country of Publication:
United States

Citation Formats

Chen, Jian, and Feng, Zhili. IR-based Spot Weld NDT in Automotive Applications. United States: N. p., 2015. Web.
Chen, Jian, & Feng, Zhili. IR-based Spot Weld NDT in Automotive Applications. United States.
Chen, Jian, and Feng, Zhili. 2015. "IR-based Spot Weld NDT in Automotive Applications". United States. doi:.
title = {IR-based Spot Weld NDT in Automotive Applications},
author = {Chen, Jian and Feng, Zhili},
abstractNote = {},
doi = {},
journal = {},
number = ,
volume = ,
place = {United States},
year = 2015,
month = 1

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  • The increasing interest in laser beam welding for automotive applications has directed the attention of many researchers to investigating the durability of laser beam welded components. In this study, a comprehensive experimental study, augmented by finite element analysis, was performed to assess the effect of laser weld pattern and location on the durability of box section T-joints. Two laser beam weld configurations were assessed: straight and optimized. Additionally, for comparison purposes, fatigue of resistance spot-welded T-joints was also evaluated. Inplane bending, at an R ratio (R = min/max load) of [minus]1, was employed for all the tests. Test results showedmore » that, on the basis of comparable weld area, laser weld configuration has a strong influence on the fatigue resistance of the T-joints. An optimized laser weld configuration was shown to provide fatigue resistance superior to a resistance spot-welded T-joint. In order to incorporate the advantages of laser beam welding, optimization of weld design should be part of the early stages of vehicle development.« less
  • The corrosion properties of weld overlays of Ni-based alloys have been investigated using different test methods. Of the different weld overlays tested, only the alloy 59 types seems to be beneficial with respect to crevice corrosion initiation compared with 6Mo base material. Both alloy C-22 and alloy C-276 weld overlays have slightly lower critical crevice temperatures (CCT`s) while alloy 625 and C-4 weld overlays have considerably lower CCT`s than the 6Mo base material. Applying a test method or using a gasket material giving less critical crevice geometry than PTFE does, the critical crevice corrosion temperature increases considerably. Care must bemore » taken when evaluating results from testing and when specifying test temperature and test method for quality control. A crevice corrosion test method simulating the condition when starting up a chlorinated seawater system has been developed.« less
  • The application of sol-gel processed materials in a variety of sensors has been proposed. The authors describe microcalorimeter sensor devices employing sol-gel processed alumina based materials which can be used to monitor pollutants in automotive exhaust. These sensors operate by measuring changes in resistance upon catalysis and are economically acceptable for automotive applications. It is important to point out that automobiles will be required to have a means of monitoring exhaust gases by on-board sensors as mandated by the EPA and the California Air Resources Board (OBD-II).
  • Abstract not provided.
  • The overall objective of this research is to develop a general model of fatigue crack propagation in resistance spot-welded joints. An important feature of this development is that the model and accompanying methodology should be accessible to designers evaluating fatigue response of structures containing multiple welds. This objective is achieved by examining the stress state around a resistance spot weld. A general expression for the structural stress around the weld is formulated that is dependent only on the loading immediately surrounding the weld; as such, it is specimen independent. In the current work, the methodology developed in Ref 2 formore » estimating propagation life is extended by explicitly considering the effects of axial loading and of load ratio on life estimates. In addition, issues related to creating an appropriate finite element model are addressed, and a number of modeling guidelines are established. Total life estimations are made and compare favorably with experimentally measured lives of welds in mild steels in a variety of specimen configurations.« less