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Keywords = electrode tip-dressing

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15 pages, 5243 KB  
Article
Substituting Resistance Spot Welding with Flexible Laser Spot Welding to Join Ultra-Thin Foil of Inconel 718 to Thick 410 Steel
by Nikhil Kumar, Sisir Dhara, Iain Masters and Abhishek Das
Materials 2022, 15(9), 3405; https://doi.org/10.3390/ma15093405 - 9 May 2022
Cited by 16 | Viewed by 4526
Abstract
This paper investigated various aspects of replacing existing micro-resistance spot welding (micro-RSW) with micro-laser spot welding for joining Inconel 718 thin foils to thick 410 steel stack-up to allow faster, non-contact joining together with flexibility in spot positioning and removal of tip dressing [...] Read more.
This paper investigated various aspects of replacing existing micro-resistance spot welding (micro-RSW) with micro-laser spot welding for joining Inconel 718 thin foils to thick 410 steel stack-up to allow faster, non-contact joining together with flexibility in spot positioning and removal of tip dressing required for RSW electrodes. The joint quality was evaluated based on the mechanical strength, microstructural characteristics and joint strength at elevated temperature as these joints are often used for high-temperature applications. Experimental investigations were performed using micro-RSW and micro-laser spot welding to obtain the 90° peel and lap shear specimens, each comprising four spots. The obtained strength from laser joints was significantly higher than that of micro-RSW joints due to larger weld nugget formation and interface width. The process map for obtaining good quality welds was also identified, and about a 17% reduction in joint strength was obtained when welded specimens were subjected to elevated temperature (i.e., 500 °C) in comparison with room temperature. This reduction was compensated for using the flexibility of laser welding to add two extra spots. The overall performance of the micro-laser spot welds was found to be better than the micro-RSW considering joint strength, flexibility in placing the spots and time to produce the welds. Full article
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20 pages, 38957 KB  
Article
General Approach for Inline Electrode Wear Monitoring at Resistance Spot Welding
by Christian Mathiszik, David Köberlin, Stefan Heilmann, Jörg Zschetzsche and Uwe Füssel
Processes 2021, 9(4), 685; https://doi.org/10.3390/pr9040685 - 13 Apr 2021
Cited by 15 | Viewed by 6291
Abstract
Electrodes for resistance spot welding inevitably wear out. In order to extend their service life, the tip-dressing process restores their original geometry. So far, however, the point in time for tip-dressing is mainly based on experience and not on process data. Therefore, this [...] Read more.
Electrodes for resistance spot welding inevitably wear out. In order to extend their service life, the tip-dressing process restores their original geometry. So far, however, the point in time for tip-dressing is mainly based on experience and not on process data. Therefore, this study aims to evaluate the in-situ or inline wear during the welding process without using additional sensors, and to base the timing for tip-dressing on continuous process monitoring, extending electrode life even further. Under laboratory conditions, electrode wear is analyzed by topographical measurements deepening the knowledge of the known main wear modes of resistance-spot-welding electrodes, mushrooming and plateau forming, and characterizing an electrode length delta over the number of spot welds. In general, electrode wear results in deformation of the electrode contact area, which influences process parameters and thereby weld quality. The conducted tests show correlation between this deformed contact area and the electrode length delta. The study shows that this electrode length delta is visible in actual process data, and can therefore be used as a criterion to characterize the wear of electrodes. Furthermore, this study gives reason to question commonly used spot-welding quality criteria and suggests different approaches, such as basing spot-welding quality on the possibility of nondestructive testing. Full article
(This article belongs to the Special Issue Process Control and Smart Manufacturing for Industry 4.0)
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