Abstract
Resistance spot welding is used as a high-productivity joining process for the increasing use of lightweight materials in industrial applications. The main challenge for the welding of aluminum alloys is the wear of the electrodes. Due to the natural oxide layers on the metal surface, high contact resistances exist between the sheet metal and the electrode. This results in increased heat generation at this interface, which leads to increased alloyage on the electrode. Breaking the insulating natural oxide layers can be achieved by a friction-free or friction-assisted motion overlay and leads to a reduced electrode wear. The complex physical correlations involved are currently being investigated in a basic research project at TU Dresden. In addition to welding tests on a test rig, simulation-based analyses are also carried out. These allow a physic-based modeling of the effects and can be used later on for an extrapolation of any resistance welding process with motion overlay. In this paper, first experimental and analytical considerations for the mechanical destruction of the oxide layer of aluminum are discussed. Subsequently, the developed extended simulation model is presented and compared according to the quality of simulation of the welding process with motion overlay. The simulation method used is a multiphysics FEM simulation with ANSYS.
Sign-in/Register to access full text options 
Talk to us
Join us for a 30 min session where you can share your feedback and ask us any queries you have
Schedule a callDisclaimer: All third-party content on this website/platform is and will remain the property of their respective owners and is provided on "as is" basis without any warranties, express or implied. Use of third-party content does not indicate any affiliation, sponsorship with or endorsement by them. Any references to third-party content is to identify the corresponding services and shall be considered fair use under The CopyrightLaw.
