Abstract
AbstractResistance spot welding, which is the dominant welding process with high productivity for manufacturing car body and other components, is widely used to weld various steel sheets in automotive industry. However, electrode indentation affects both the surface quality and mechanical property of resistance spot welded lap joint. Variation in the tip diameter of upper electrode and use of copper plate at the lower electrode side are an effective recourse to get sound surface appearance with reduced indentation depth due to lower current intensity. In present study, with 10 mm thick copper plate on lower electrode side, resistance spot welding of 1.2 and 1.6 mm thick cold rolled steel sheets has been performed to examine the effect of upper electrode tip diameter on formation of indentation depth and nugget diameter. The result exhibits that larger electrode tip diameter significantly reduced indentation depth on optimal nugget size corresponding to Korean Industrial Standard requirements for resistance spot welding. In case of welding in 1.2 mm thick steel sheets using electrode tip diameter of 8 mm, nugget diameter increased with increasing welding current and then the maximum tensile shear load was 6.55 kN under welding current of 10 kA. The maximum tensile shear load of 1.6 mm thick steel sheets reached 11.28 kN under welding current of 11 kA.KeywordsResistance spot weldingCopper plateIndentation depthNugget diameterMechanical properties
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