Abstract
The article discusses the optimisation of the conventional resistance welding process performed using the pneumatic (electrode) force system (PFS) by applying the electromechanical force system (EFS) and a new algorithm enabling the control of the force and/or displacement of welding machine electrodes, particularly during the flow of current. The research work described in the article aimed at the in-depth numerical analysis of the projection cross-wire welding of bars made of aluminium alloy Al 5182, having a diameter of 4 mm, in relation to two electrode force systems, i.e. the PFS and the EFS. The research-related tests involved experimental verification. In addition, the article presents advantages of the new control system. Calculations were performed until one of the adopted boundary conditions, i.e. the maximum welding time, the maximum penetration of wires (bars), the occurrence of expulsion or the exceeding of the temperature limit in the contact between the electrode and the welded material was obtained. For the PFS, it was observed that the ring weld was formed within the entire range of welding parameters. Numerical calculations were performed using SORPAS software. Technological welding tests were performed using inverter welding machines (1 kHz) provided with various electrode force systems. The research also involved the performance of metallographic and strength (peeling) tests as well as measurements of welding process characteristic parameters (welding current and voltage). The welding process optimisation involving the use of the EFS and the application of the hybrid algorithm of force control resulted in (i) more favourable space distribution of welding power, (ii) energy concentration in the central zone of the weld, (iii) favourable (desired) melting of the material within the entire weld transcrystallisation zone, (iv) obtainment of a full weld nugget and (v) over 20% longer weld nugget diameter.
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