Abstract
This study focused on the nugget formation in resistance welding of three dissimilar steel sheets influenced by different types and thicknesses of epoxy adhesive. An improved finite element model was employed to estimate the temperature distribution in three-sheet weld-bonding and was validated by the metallographic tests. Results showed that the weld initiation time and corresponding nugget size for weld-bonds would be earlier and larger than that of resistance spot welds in term of the same welding parameters. Compared to the adhesive Betamate Flex, the weld-bonding joint of three-sheets with adhesive Terokal 5089 would have a greater increment of the weld nugget sizes due to the increase of the static contact resistance brought by the interfaces between the steel sheets. However, the bond line thickness of the previously mentioned adhesive would take little effect on the weld sizes in weld-bonding of three dissimilar steel sheets.
Highlights
The weld-bonding process is a typical hybrid welding process that combines the technical benefits of resistance spot welding (RSW) and adhesive bonding (AB)
The adhesive would flow and the bond line thickness would decrease when the electrode force is applied on the steel sheets in the squeeze cycle
The steel sheets would deform a little and, the distribution of the adhesive would become uneven during the squeeze cycle
Summary
The weld-bonding process is a typical hybrid welding process that combines the technical benefits of resistance spot welding (RSW) and adhesive bonding (AB). Further studies have proven that the increase of the weld sizes would be attributed to the increase of the contact resistance by putting the adhesive into the interfaces between the steel sheets. It is essential a detailed of the weld-bonding of three of three sheets with types different line thicknesses of be adhesive be obtained. Since betweencurrent two work pieces can be expressed bythe theadhesive equationwould below.stick to the steel surface even if an electrode force is loaded, it is vital to analyze the effect of the residual adhesive on the static contact resistance at the faying area in the squeeze cycle. This work, residual on the adhesive contact resistance can be expressed in a In similar way the to the termadhesive of the film the steel surface considered as one additional the interface. Same time, this increment of the contact resistance decreases when the electrode force goes up
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