Abstract
For several decades, the electrical resistance spot welding process has been widely used in the manufacturing of sheet metal structures, especially in automotive bodies. During this period there was no significant development for this welding process. However, in recent years, in order to meet the demand for lighter, economical, and low-cost vehicles, the automotive manufacturing industry is undergoing a revolution in the use of high strength steel sheet combinations, chemical compositions, and of different thicknesses. In this context, the present work focuses on the study and development of a new resistant spot welding technology using additive manufacturing (AMSW) in zinc-coated steel sheets, used in the automotive industry. As a comparison, spot welding was also performed by the conventional resistance spot welding process (RSW). The results showed that the spot welding process using additive manufacturing (AMSW), through the optimized parameters, compared to the conventional resistance spot welding process (RSW), was 34.47% higher in relation to the shear tensile stress, as well as 28.57% higher tensile stress with a perpendicular load to the weld spot. The indentation or thermomechanical mark on the surface of the sheet was imperceptible to the visual inspection, producing a smooth face in the spot region.
Highlights
Resistance spot welding (RSW) is the most used process in the assembly of structures, such as automobiles, trucks, airplanes, train cars, etc
These were selected through a spotinof greatest freedom, welding parameters, within the area of the diagram
The dilution between the deposited and the base that material was process total, using the optimized parameters, in zinc coated sheets, itmetal can be concluded this new of spot optimized parameters, in zinc coated sheets, it can be concluded that this new process of spot welding using additive manufacturing (AMWS) is by melting and pressing
Summary
Resistance spot welding (RSW) is the most used process in the assembly of structures, such as automobiles, trucks, airplanes, train cars, etc. An average of 4000 weld spots is required in an automobile body assembly [1,2,3]. The formation of the weld spot and its behavior during welding is expected to be different when this spot is made on these new circumstances [4,5,6,7,8]. This phenomenon is due to the fact that the amount of thermal energy generated during welding depends on three main factors: the electric current, the electrical resistance of the conductor, and the current time
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