Developments in characterization of resistance spot welding of aluminum

Hao, M. and Osman, K.A. and Boomer, D.R. and Newton, C.J. (1996) Developments in characterization of resistance spot welding of aluminum. Welding Journal (Miami, Fla), 75 (1). 1-s.

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Abstract

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.

Item Type: Article
Additional Information: cited By 52
Uncontrolled Keywords: Aluminum; Automobile manufacture; Automotive engineering; Data acquisition; Data reduction; Monitoring; Regression analysis; Resistance welding; Statistical methods; Tensile strength; Welds, Aluminum vehicles; Automobile industry; Linear regression; Monitoring system; Resistance spot welding, Spot welding
Subjects: H300 Mechanical Engineering
H400 Aerospace Engineering
H700 Production and Manufacturing Engineering
Divisions: Faculty of Computing, Engineering and the Built Environment > School of Engineering and the Built Environment > Advanced Design Engineering
Faculty of Computing, Engineering and the Built Environment > School of Engineering and the Built Environment > Advanced Systems Engineering
Depositing User: Prof Keith A. Osman
Date Deposited: 05 Apr 2016 08:50
Last Modified: 05 Apr 2016 12:47
URI: http://www.open-access.bcu.ac.uk/id/eprint/48

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