The Asymmetric Laplace Law for distribution of aluminum contact resistance in spot welding

This paper investigates the distribution of contact resistance of the aluminum alloy in the squeeze stage. A new method of measuring path＇ s resistance is proposed firstly. Contact resistances are calculated accurately by the systems of 5 linear equations and solutions show that three contact resistances are different. The probability density functions of contact resistance in workpiece/workpiece（ W/W） and upper electrode/workpiece（ E/W） show that the curve shape has steeper peak and heavier tail than that of the normal distribution. Non-parameter hypothesis test is performed and the result shows that R2 , R4 reject the normal distribution using chi-square and kolmogoroo statistic D method. Therefore, the Asymmetric Laplace distribution is fitted to empirical distributions and is applied to quantify the influence of random contact resistance. The result illustrates that AL distribution is very close to contact resistance of W/W and upper E/W and normal distribution has some deviation. The paper is helpful to research the initial nugget conditions, weldability and the transient multi-coupling field.

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.

Analysis of Acoustic Emission Signal by Fractal Theory in Aluminum Alloy Spot Welding

The relation between acoustic emission signal and nugget during aluminum alloy spot welding was investigated in order to evaluate spot welding quality. Due to the nonlinearity of the signals, fractal theory was utilized to quantitatively describe the characteristics of the signals instead of classical Euclidean geometry which cannot describe the acoustic emission signal accurately. Through experiments and computing, the box counting dimension is found distinct from other acoustic emission signals and is a better approach to discriminating weld nugget stages. Results show that fractal dimensions increase from 1.51 to 1.78,and they are related to nugget areas added from non-fusion to over-heated nugget. And the box counting dimension can effectively evaluate the quality of the nugget in the spot welding and can be aoolied with current, displace, and other soot welding parameters.