Abstract
Resistance spot welding has been widely used for joining sheet metals, especially in automotive and aerospace industries. However, since the formation of weld nugget is invisible in resistance spot welding, traditionally off-line destructive test is applied for inspection of the weld quality, which is costly and inefficient. Therefore, in recent years, a lot of efforts have been made in estimating or detecting the weld quality nondestructively by on-line welding parameter monitoring. This paper presents a review on techniques of monitoring resistance spot welding process or weld quality, and the advantages as well as limitations of these techniques are discussed.
Highlights
Resistance spot welding (RSW) is widely used for joining sheet metals and is recognized as the most rapid and economic joining method, its unique advantages have kept it as one of the most productive and competitive joining technologies in automotive, aerospace, and other metal processing industries [1,2,3,4]
In addition there is a large number of interrelated variables in resistance welding; weld quality is extremely operation dependent and varied from part to part due to such changes as workpiece surface condition, electrode tip fit-up, circuit impedance, shunt effect, and so forth in recent years, a lot of efforts have been made in estimating or detecting the weld quality nondestructively by on-line welding parameter monitoring or on-line visual inspection of the welding spot, which is especially beneficial to the continuous production of automated system as the faults may be immediately identified and rectified [5, 6]
The parameters monitored for weld quality detection are classified into two types: one is the parameters related to the power input of the welding process and the other is the one related to mechanical response, such as dynamic electrode displacement, applied electrode force and acoustic emission
Summary
Resistance spot welding (RSW) is widely used for joining sheet metals and is recognized as the most rapid and economic joining method, its unique advantages have kept it as one of the most productive and competitive joining technologies in automotive, aerospace, and other metal processing industries [1,2,3,4]. In addition there is a large number of interrelated variables in resistance welding; weld quality is extremely operation dependent and varied from part to part due to such changes as workpiece surface condition, electrode tip fit-up, circuit impedance, shunt effect, and so forth in recent years, a lot of efforts have been made in estimating or detecting the weld quality nondestructively by on-line welding parameter monitoring or on-line visual inspection of the welding spot, which is especially beneficial to the continuous production of automated system as the faults may be immediately identified and rectified [5, 6]. In-process weld quality monitoring or control is still not universally proved, it is certainly the ideal and promising approach [7, 8]. A comprehensive review on monitoring resistance spot welding process or weld quality is presented
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