Developments in characterization of resistance spot welding of aluminum

Journal Article · Mon Jan 01 04:00:00 EST 1996 · Welding Journal

OSTI ID:197651

Hao, M; Osman, K A ^[1]; Boomer, D R ^[2]; Newton, C J ^[3]

---

1. Univ. of Central England, Birmingham (United Kingdom)
2. Alcan Rolled Products Co., Farmington Hills, MI (United States)
3. Alcan International Ltd., Banbury (United Kingdom). Banbury Labs.

Automotive industry interest in aluminum is growing rapidly in Europe and North America. Resistance spot welding and weldbonding will be key techniques in the volume production of aluminum vehicles. A monitoring system has been developed to collect process data during single-phase alternating current (AC) and medium-frequency direct current (MFDC) inverter resistance welding. Features extracted from the captured data are used to characterize spot welding and to identify a range of process phenomena. Statistical analysis has been applied to investigate the relationship between the extracted features and the conventional physical parameters, e.g., weld size and static tensile strength. Welding trials using both MFDC and AC welding equipment have been carried out using aluminum of different gauges and surface conditions. Results on the Al-Mg alloy AA-5754 have shown that the monitoring methods developed previously for steel do not appear to be generally applicable to aluminum. No single parameter can accurately quantify weld quality. Multiple regression methods can, however, provide good prediction of nugget diameter and static strength. This has proved effective even when only electrical variables are logged, removing the need for measurement of other process signals, e.g., electrode displacement or force.

• OSTI ID: 197651
• Journal Information: Welding Journal, Journal Name: Welding Journal Journal Issue: 1 Vol. 75; ISSN 0043-2296; ISSN WEJUA3
• Country of Publication: United States
• Language: English

Related Subjects

33 ADVANCED PROPULSION SYSTEMS
36 MATERIALS SCIENCE
ALUMINIUM BASE ALLOYS
AUTOMOBILES
MAGNESIUM ALLOYS
MATERIALS
MONITORING
PROCESS CONTROL
RESISTANCE WELDING
TENSILE PROPERTIES
WEIGHT