Chaos analysis of acoustic emission signals in spot welding process

Based on chaos time series and fractal theory, acoustic emission signals were studied in the process of spot welding. According to calculating 8 welding parameters using phase space reconstruction method, the largest Lyapunov exponents were positive values and chaos characteristics were firstly discovered from acoustic emission signals in spot welding. In order to evaluate acoustic emission signal, Hausdorff dimension is put forward to analyze and estimate chaos characteristics. The experiment and calculation results indicate that the Hausdorff dimension of acoustic emission signal is significantly distinguishable in the nuggets with different welding parameters. This research provides a new method for measuring the resistance spot welding quality.

Design of Fully Automatic Specification Selection System for Resistance Welding Equipment

A system for fully automatic selection of welding specifications in resistance welding equipment has been developed to address the problem of workers frequently choosing the wrong specifications during manual welding of multiple parts on a single machine in automobile factories. The system incorporates an automatic recognition system for different workpiece materials using the added machine fixture,visual detection system for nuts and bolts,and secondary graphical confirmation to ensure the correctness of specification calling. This system achieves reliable,fully automatic selection of welding specifications in resistance welding equipment and has shown significant effects in improving welding quality for massproduced workpieces,while solving the problem of specification calling errors that can occur with traditional methods involving process charts and code adjustments. This system is particularly suitable for promoting applications in manual welding of multiple parts on a single machine in automobile factories,ensuring correct specification calling and welding quality.

Friction stir keyholeless spot welding of AZ31 Mg alloy-mild steel

Friction stir keyholeless spot welding（FSKSW） using a retractable pin for 1.0 mm thick galvanized mild steel and 3 mm thick AZ31 B magnesium alloy in a lap configuration was investigated.The process variables were optimized in terms of the joint strength.The effects of the stacking sequence on joint formation and the joining mechanism of FSKSW AZ31B-to-mild steel joints were also analyzed.It shows that the process window and joint strength are strongly influenced by the stacking sequence of the workpieces.While the process window is narrow and unstable for FSKSW of a magnesium-to-steel stack-up,a desirable process was established for the steel-to-magnesium stacking sequence,a desirable process and higher strength joint can be got when the steel-to-magnesium stacking sequence.XRD phase and EPMA analyses of the FSKSW joint showed that the intermetallic compounds are formed at the steel-to-magnesium interface,and the element diffusion between the mild steel and AZ31 B magnesium alloy revealed that the joining methods for FSKSW joints is the main mechanical joining along with certain metallurgical bonding.

Multi-field dynamic modeling and numerical simulation of aluminum alloy resistance spot welding

In order to explore the influence of welding parameters and to investigate the Al alloy (AA) nugget formation process, a comprehensive model involving electrical-thermal-mechanical and metallurgical analysis was established to numerically display the resistance spot welding (RSW) process within multiple fields and understand the AA-RSW physics. A multi-disciplinary finite element method (FEM) framework and a empirical sub-model were built to analyze the affecting factors on weld nugget and the underlying nature of welding physics with dynamic simulation procedure. Specifically, a counter-intuitive phenomenon of the resistance time-variation caused by the transient inverse virtual variation (TIVV) effect was highlighted and analyzed on the basis of welding current and temperature distribution simulation. The empirical model describing the TIVV phenomenon was used for modifying the dynamic resistance simulation during the AA spot welding process. The numerical and experimental results show that the proposed multi-field FEM model agrees with the measured AA welding feature, and the modified dynamic resistance model captures the physics of nugget growth and the electrical-thermal behavior under varying welding current and fluctuating heat input.

Microstructure and mechanical properties of Mg-to-Al dissimilar welded joints with an Ag interlayer using ultrasonic spot welding

Lightweight ZEK100-0 Mg alloy and A16022-T43 Al alloy with an Ag interlayer were joined via ultrasonic spot welding(USW),focusing on the microstructural change and tensile lap shear strength of the welded joints in relation to welding energy.Mg/Al interface was superseded by Mg/Ag and Al/Ag interfaces,and unfavorable Mg门A-intermetallic compound was eliminated.Ag foil was observed to be intact in the nugget center,while it was broken or dissolved at the nugget edge at high welding energy levels.The diffusion layer at the Mg/Ag interface consisted of two distinctive sub-layers:Mg3Ag intermetallic compound adjoining Ag foil,and Mg3Ag-l-Mg eutectic structure adjacent to Mg.Only a thin diffusion layer consisting mainly of Ag3Al occurred al lhe Al/Ag interface.The tensile lap shear strength first increased,reached its peak value,and then decreased with increasing welding energy.The shear strength achieved in the present study was〜31%higher than that of the joint without interlayer.Interfacial failure occurred at all energy levels,with Ag foil particles or fragments being stuck on both Mg and Al sides due to its intense interaction with Mg and Al via accelerated diffusion during USW.The results obtained pave the way for the challenging dissimilar welding between Mg and Al alloys.

Microstructure and properties of probeless friction stir spot welding of AZ31 magnesium alloy joints

The AZ31 magnesium alloy with a thickness of 1.8 mm was welded by the probeless friction stir spot welding process without Zn interlayer.The influence of process parameters on joint microstructure and mechanical properties was investigated by using different rotating speeds and dwell time.Microstructure of joints is divided into three regions:stir zone,thermomechanically-affected zone and heat-affected zone.With the increase of rotation speed and dwell time,the depth of stir zone gradually increases,and hook defects extend from the interface of two plates to the surface of the upper plate.The tensile shear strength of joints and two fracture modes(shear fracture and plug fracture)are closely related to hook defects.The maximum tensile shear strength of the joint is 4.22 kN when rotation speed and dwell time are 1180 r/min and 9 s,respectively.Microhardness value and its fluctuation in upper sheet are evidently higher than those of the lower sheet.

Study of joining mechanism of ABS polymer and steel/aluminum by resistance spot welding

The joining of metal and polymer is an increasingly important method to get lightweight components in the development of manufacturing industry- nowadays. In this artiele, metal and polymer lap joint was achieved by means of resistance spot welding （RSW） and ultrasonic assistance welding （UAW）. The joining mechanism of lap joint was analyzed by OM, TEM on microstructure at the interface of lap joints and XPS and IR spectra was discussed based on the following different ones： mechanical-interlocking, diffusion bond and coordination bond. The results showed that it was the combined action that played an important role in the effective joining work. Besides, ultrasonic assistance was used in the study to aid welding process based on its high-frequency ultrasonic vibration, which made joints shaping better and improved tensile strength visibly contrast to joints with the same lower heat input parameters.

Numerical simulation on temperature field for resistance spot welding of non-equal thickness stainless steel

An axisymmetric finite element model is developed to simulate the temperature field of resistant spot welding according to the process characters of nugget formation of non equal stainless steel sheets. A simulation method of the interaction of electrical and thermal factors is presented. The spot welding process of nugget formation is simulated using hard and soft welding technique norms. The heating characters of soft and hard norms determine the differences in the process of nugget formation and determine the finally shape and offset of nugget. Experimental verification shows that the model prediction agrees well with the practical.

Ultrasonic C-scan Detection for Stainless Steel Spot Welding Based on Wavelet Package Analysis

An ultrasonic test of spot welding for stainless steel is conducted. Based on wavelet packet decomposition, the ultrasonic echo signal has been analyzed deeply in time - frequency domain, which can easily distinguish the nugget from the corona bond. The 2D C-scan images produced by ultrasonic C scan which contribute to quantitatively calculate the nugget diameter for the computer are further analyzed. The spot welding nugget diameter can be automatically obtained by image enhancement, edge detection and equivalent diameter algorithm procedure. The ultrasonic detection values in this paper show good agreement with the metallographic measured values. The mean value of normal distribution curve is 0.006 67, and the standard deviation is 0.087 11. Ultrasonic C-scan test based on wavelet packet signal analysis is of high accuracy and stability.

DETECTION METHOD OF SPOT WELDING BASED ON MULTI-INFORMATION FUSION AND FRACTAL

A novel detection method of support vector machine （SVM） based on fractal dimension of signals is presented. And models of SVM are made based on nugget size defects of spot welding. Classification using these trained SVM models is done to signals of spot welding. It is shown from effect of different SVM models that these models with different inputs. In detection of defects, these models with inputs including sound signal have a high percentage of accuracy, the detection accuracy of these models with inputs including voltage signal will reduce. So the SVM models based on fractal dimensions of sound are some optimal nondestructive detection ones. At last a comparison between SVM detection model and ANNS detection model is researched which indicates that SVM is a more effective measure than Artificial neural networks in detection of nugget size defects during spot welding.

Numerical simulation of deep cryogenic treatment electrode tip temperature for spot welding aluminum alloy

Deep cryogenic treatment technology of electrodes is put forward to improve electrode life of resistance spot welding of aluminum alloy LF2. Deep cryogenic treatment makes electrode life for spot welding aluminum alloy improve. The specific resistivity of the deep cryogenic treatment electrodes is tested and experimental results show that specific resistivity is decreased sharply. The temperature field and the influence of deep cryogenic treatment on the electrode tip temperature during spot welding aluminium alloy is studied by numerical simulation method with the software ANSYS. The axisymmetric finite element model of mechanical, thermal and electrical coupled analysis of spot welding process is developed. The numerical simulation results show that the influence of deep cryogenic treatment on electrode tip temperature is very large.

Effect of deep cryogenic treatment on mechanical behavior of a Cu-Cr-Zr alloy for electrodes of spot welding

The effects of deep cryogenic treatment on mechanical behavior of a Cu-Cr-Zr alloy for electrodes of spot welding were investigated employing Brinell-hardness testing unit, abrasion examination machine, electronic almighty testing machine and X-ray stress analyzer. Tensile fracture surfaces of the alloy were characterized by scanning electronic microscope （SEM） with energy dispersive X-ray spectroscopy （EDS）. The results showed that, after deep cryogenic treatment, σb and σ0.2 increased 23 MPa and 21 MPa respectively, the wear rate of the alloy exhibited the trend of decrease with the decreasing temperature and increasing time of deep cryogenic treatment, and the surface residual stress of the alloy was partially eliminated by deep cryogenic treatment.

Comparative study of resistance spot welding performance between cold-rolled DP980 and Q&P980 steels

Advanced high strength steel (AHSS) has been widely used in the automobile industry.The resistance spot welding performance of DP980 and Q&P980 steels was studied through comparing the two steels’welding current range,tensile shear strength (TSS),cross tension strength (CTS),weld spots’microhardness,etc.The following conclusions were achieved:It is easy for both DP980 and Q&P980 steels to get a nugget size bigger than 4 mm,they all have welding current ranges exceeding 2 kA and high weld strength.

Dissimilar ultrasonic spot welding of Mg-Al and Mg-high strength low alloy steel

Sound dissimilar lap joints were achieved via ultrasonic spot welding （USW）, which is a solid-state joining technique. The addition of Sn interlayer during USW effectively blocked the formation of brittle Al12Mg17 intermetallic compound in the Mg-Al dissimilar joints without interlayer, and led to the presence of a distinctive composite-like Sn and Mg2Sn eutectic structure in both Mg- Al and Mg-high strength low alloy （HSLA） steel joints. The lap shear strength of both types of dissimilar joints with a Sn interlayer was significantly higher than that of the corresponding dissimilar joints without interlayer. Failure during the tensile lap shear tests occurred mainly in the mode of cohesive failure in the Mg- Al dissimilar joints and in the mode of partial cohesive failure and partial nugget pull-out in the Mg-HSLA steel dissimilar joints.

A MULTI-COUPLED FINITE ELEMENT ANALYSIS OF RESISTANCE SPOT WELDING PROCESS

A two-dimensional axisymmetric finite element model is developed to analyze the transient thermal and mechanical behaviors of the Resistance Spot Welding （RSW） process using commercial software ANSYS. Firstly a direct-coupled electrical-thermal Finite Element Analysis （FEA） is performed to analyze the transient thermal characteristics of the RSW process. Then based on the thermal results a sequential coupled thermo-elastic-plastic analysis is conducted to determine the mechanical features of the RSW process. The thermal history of the whole process and the temperature distribution of the weldment are obtained through the analysis. The mechanical features, including the distributions of the contact pressure at both the faying surface and the electrode-workpiece interface, the stress and strain distributions in the weldment and their changes during the RSW process, the deformation of the weldment and the electrode displacement are also calculated.

Filling technique for keyhole of friction stir spot welding based on the principles of resistance spot welding

Keyhole at the end of a weld prepared by friction stir welding(FSW)is one of the major issues that impede the application of FSW.To address this issue,a keyhole filling technique was proposed in this paper,which is based on the principles of resistance spot welding(RSW).A three-phase secondary rectifier resistance spot welder was applied as the experimental instrument for filling the keyhole in the center of friction stir spot weld(FSSW).The test sheet is a 2024-T4 aluminium alloy with a thickness of 6.0mm.The experiments results show that the filled joint strength is improved by 26.12%since the area is increased for the plug in the keyhole.And there are two kinds of dimples in the tensile fracture-equiaxial dimples and long dimples.The filled joint involves the fusion welding zone(FWZ),pressure welding zone(PWZ),melted plug zone(MPZ),and plastic deformation zone(PDZ).The FWZ and the PWZ is the melting bond and diffusion bond between the plug and keyhole,respectively.The MPZ is the center part and the PDZ is upper or lower part of the plug.

Visual sensing and morphological image processing of weld pool in laser spot welding

A visual sensing system was established to monitor the weld pool in laser spot welding. The top-hat and bottom-hat transformation algorithms based on mathematical morphology were used to compensate for non-uniform contrast of weld pool edge. Moreover, the canny edge detector was applied to extract the weld paol profile. The edge detected results show that the morphological operation is obviously superior to the traditional contrast enhancement method. In addition, the combination of dilation and erosion was applied to eliminate the irrelevant edge details, and the smooth weld pool edge was acquired. Based on the image processing technology described above, the dynamic process of weld pool diameter during laser spot welding was obtained.

Application of the wavelet packet and its energy spectrum to identify nugget splash during the aluminum alloys spot welding

Nugget splash during aluminum alloys spot welding has a detrimental effect on weld nugget integrity, strength and durability of the welded joints. This investigation is performed to identify nugget splash from voltage signals because these are easily accessible on-line. In the present work, we propose a novel method based on the wavelet packet transform and its energy spectrum for pattern recognition of splash signal. The result demonstrates that this novel method is more accuracy and a useful way of monitoring the spot welding quality.

SPOT WELDING QUALITY FUZZY CONTROL SYSTEM BASED ON MULTISENSOR INFORMATION FUSION

The multisensor information fusion technology is adopted for real time measuring the four parameters which are connected closely with the weld nugget size（welding current, electrode displacement, dynamic resistance, welding time）, thus much more original information is obtained. In this way, the difficulty caused by measuring indirectly weld nugget size can be decreased in spot welding quality control, and the stability of spot welding quality can be improved. According to this method, two-dimensional fuzzy controllers are designed with the information fusion result as input and the thyristor control signal as output. The spot welding experimental results indicate that the spot welding quality intelligent control method based on multiscnsor information fusion technology can compensate the influence caused by variable factors in welding process and ensure the stability of welding quality.

Structural Stress-Fatigue Life Curve Improvement of Spot Welding Based on Quasi‑Newton Method

ΔF-N curves are usually used to predict the fatigue life of spot welding in engineering,but they are time-consuming and laborious and not universal.For the purpose of predicting the fatigue life of spot welding accurately and efficiently,tensile-shear fatigue tests were conducted to obtain the fatigue life of spot-welded specimens with different sheet thicknesses combinations.These specimens were simulated by using the finite element method,and the structural stress was theoretically calculated.In the double logarithmic coordinate system,the structural stress-fatigue life(S-N)curve of spot welding was fitted by the least-squares method,based on the quasi-Newton method.The square of the correlation coefficient of the S-N curve was taken as the optimization objective,with the correction coefficients of force,bending moment,spot welding diameter,and sheet thickness as the variables.During the optimization process,three different ways were utilized to get three optimized spot welding S-N curves,which are suitable for different situations.The results show that the fitting effect of the S-N curve is improved,the data points are more compact,and the optimization effect is significant.These S-N curves can be used to predict the fatigue life,which provide the basis for practical engineering application.