Abstract
Effect of process variables (electrode pressure, holding time, welding current, and welding time) on low-carbon steel resistance spot welds performance has been investigated in this paper. Failure mode, peak load, and maximum energy obtained in tensile-shear test have been used to describe spot welds performance. Excessive electrode pressure can reduce both peak load and maximum energy, considerably. Holding time does not significantly affect peak load and maximum energy for investigated material. Increasing welding time and welding current to some extent increases both peak load and maximum energy. However, excessive welding time and welding current not only do not increase weld nugget size and peak load, but also decrease maximum energy.
Highlights
Resistance spot welding has been the dominant process in sheet metal joining
To ensure and maintain structural integrity of finished component under a wide range of operating conditions, for example a crash situation, the remotest possibility of producing even one or two defective welds in a critical component needs to be eliminated. These requirements, coupled with uncertainties about weld quality due to the difficulty of applying nondestructive tests to spot welds, are responsible for the practice of making more spot welds than what is needed for maintaining structural integrity
The data points for peak load and failure energy are averages of the measured values for the three specimens
Summary
Resistance spot welding has been the dominant process in sheet metal joining. To ensure and maintain structural integrity of finished component under a wide range of operating conditions, for example a crash situation, the remotest possibility of producing even one or two defective welds in a critical component needs to be eliminated. These requirements, coupled with uncertainties about weld quality due to the difficulty of applying nondestructive tests to spot welds, are responsible for the practice of making more spot welds than what is needed for maintaining structural integrity. Significant cost associated with overwelding provides a considerable driving force for optimizing this process
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