Abstract
The in-process changes of weld nugget growth during the Resistance Spot Welding were investigated based on the resistance of input electrical impedance. To compute the time varying resistance of input electrical impedance, the welding voltage and current signals are measured simultaneously and then converted into complex-valued signals by using Hilbert transform. Comparing with the dynamic contact resistance as reported in literature, it showed that the time varying resistance of input electrical impedance can be accurately correlated with the physical changes of weld nugget growth. Therefore, it can be used to characterize the in-process changes of weld nugget growth. Several new findings were reported based on the investigation of spot welds under no weld, with and without weld expulsion conditions.
Highlights
Resistance Spot Welding (RSW) has been broadly used for the structural joints due to its advantages such as easy-to-use, low cost, clean working environment and short process time
A weld nugget is formed at the sheet-to-sheet interface of metal sheets due to the heat generation by the resistances to the flow of high electric current within a short period of time
The incorrect location of the first peak could be caused by the rough measurement of dynamic contact resistance, which only considers the instant voltage and current at its peak value within every half cycle
Summary
Resistance Spot Welding (RSW) has been broadly used for the structural joints due to its advantages such as easy-to-use, low cost, clean working environment and short process time. A weld nugget is formed at the sheet-to-sheet interface (faying interface) of metal sheets due to the heat generation by the resistances to the flow of high electric current within a short period of time. Electrode force is applied through the electrodes to bring the metal sheets into contact. How to cite this paper: Wong, Y.-R. and Pan, X. (2014) A New Characterization Approach of Weld Nugget Growth by Real-Time Input Electrical Impedance.
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