Abstract
This work is aimed at the analysis of the dynamic resistance, electrical energy and behavior of the force between electrodes (including thermal expansion) during welding at optimized parameters, referring to the process of spot welding using additive manufacturing (AMSW). For comparative purposes, this analysis also includes the conventional resistance spot welding process (RSW). The experiments were done on low carbon-zinc-coated sheets used in the automotive industry. The results regarding the welding process using additive manufacturing (AMSW), in comparison to the conventional resistance spot welding (RSW), showed that the dynamic resistance presented a different behavior due to the collapse of the deposition at the beginning of the welding, and that a smaller magnitude of electrical energy (approximately <3.35 times) is required to produce a welding spot approved in accordance with the norm. No force of thermal expansion was observed during the passage of the current, in contrast, there was a decrease in the force between the electrodes due to the collapse of the deposition at the beginning of the welding.
Highlights
The resistance spot welding process (RSW) is generally used to join sheets with similar thickness and chemical compositions
In order to improve the weldability of the different sheets that constitute the current vehicle bodies, a new spot welding process using additive manufacturing (AMSW) was used in this work [12], due to its intrinsic characteristics of performing a deposition before welding from several types of materials, in different geometric formats with considerable precision [13,14,15]
Was different when compared welding process (RSW). This result is related to the collapse of the deposition due to its welding process (RSW)
Summary
The resistance spot welding process (RSW) is generally used to join sheets with similar thickness and chemical compositions. The main advantages of this process include ease of automation and high-speed welding. This process has been widely used for decades, in the automotive industry [1,2,3,4,5]. This process may seem simple, it is necessary to control a large number of variables to produce satisfactory welding in an automated, high-speed production environment. In order to improve the weldability of the different sheets that constitute the current vehicle bodies, a new spot welding process using additive manufacturing (AMSW) was used in this work [12], due to its intrinsic characteristics of performing a deposition before welding from several types of materials, in different geometric formats with considerable precision [13,14,15]
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