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I. INTRODUCTION
Resistance spot welding is widely used in sheet metal
fabrication as an important metal joining process. It has got lot
of applications in the field of automobile industries, rail coach
manufacturing, aerospace and nuclear sectors, electric and
electronic industries. It can be used on a variety of materials
such as low carbon steel, nickel, aluminium, titanium, copper
alloy, and stainless steel and high strength low alloy
steel. These steels are heat treated and consequently the effects
of temperature can influence the mechanical and corrosion
resistant properties. It is sometimes necessary to localize the
heat affected zone or heat treat the assembly after joining.
Martensitic steels are magnetic [1]. Two or more dissimilar
metallic materials are welded together and its mechanical,
microstructure properties were completely analyzed with the
application in rail and automobiles industries. And the examine
its quality in different aspects.[2] In the present work, the effect
of spot welding parameters (welding current, weld time,
electrode force) on failure load of resistance spot welds of
austenitic stainless steel (304L grade ) sheets (0.5 mm to 2.0
mm thick) were analyzed. High corrosion resistance, good
weldability and aesthetic looks are the most beneficial features
which make the use of 304L grade stainless steel superior to
carbon steel and other grades of stainless steel. [3] In order to
study the significance of the process parameters i.e. current,
electrode force and weld cycles, percentage improvement in
9256
International
JournalThe
of Applied
Research
ISSNvariables
0973-4562when
Volume
10, Number
9 (2015)
material hardness was
examined.
S/N Engineering
ratio analysis
input
defective
welds
have been detected in
Research
Publications
http://www.ripublication.com
suggested third level of weld current,third
level India
of weld
cycle :::automobile
assembly line.
and third level of electrode force as the best levels for
The areas chosen for most of the works by researchers in the
maximum percentage improvement in hardness of ASS316 past have been found as process modelling and finite element
work-piece in spot welding operation. This study helps us to analysis, dissimilar metal welding, failure mode analysis,
find out the optimum values for three parameters for Resistance parametric optimization and characterization of resistance spot
Spot Welding for 0.5mm thickness of ASS316 sheet [4] welds
Resistance spot welding (RSW) was employed to pre-join
II. EXPERIMENTAL INVESTIGATION
refractory alloy 50Mo50Re (wt%) sheet with a 0.127 mm
gage. Five important welding parameters (hold time, electrode, A. Material preparation:
ramp time, weld current and electrode force) were adjusted in
an attempt to optimize the welding quality. It was found that
Materials should be free from rust, scale, paint, dirt and
increasing the hold time from 50 ms to 999 ms improved the other insulating materials. These can cause variability of weld
weld strength. Use of rod-shaped electrodes produced quality, increase the wear of electrodes, and may also cause
symmetric nugget and enhanced the weld strength. [5] The weld splash and surface splash. Surfaces are normally
standard size (200 - 25 - 1 mm) for the base metals was degreased for aerospace quality welds and a mechanical or
prepared and welded according to the weld schedule as lap chemical treatment may be used to achieve improved
joints. The first category was only the mild steel joints, whereas, consistency. This is particularly true for aluminium alloys
the second category was only 302 austenitic stainless steel. The where a consistent surface resistance is essential.
third category was mixed base metals of mild and 302
austenitic stainless steels [6] Transformation induced plasticity
(TRIP) and twinning induced plasticity (TWIP) effects had
been widely studied in single austenite steel. But in duplex &
() phase, such as welding materials of stainless steel, they
had been less studied. Tensile shear loading experiment of
resistance spot welding specimens prepared with 2 mm 301L
sheets, was carried out at 15C and 50C. Optical microscopy
Fig 1
Resistance spot weld specimen
and scanning electron microscopy (SEM) as well as X-ray
diffraction (XRD) were used to investigate the microstructure
Where specific surface treatments are provided by the
of weld nugget, and specimens fracture surface. [7]The
material
supplier (for use with resistance welding and adhesive
interfacial to pullout failure mode transition during the tensile
bonding,
for example), these should not be removed, otherwise
shear and cross-tension test is investigated and analysed. The
joint
performance
could be seriously affected.
tensile-shear sample geometry is chosen as a representative
case for predominantly shear load (i.e., shear force to the
sheet/sheet interface). The cross-tension test is chosen as a B. Weld parameters of resistance spot welding:
(i) Welding Current
representative case for the predominantly tensile loading
The welding current is the most essential stricture in
condition (i.e., normal force to the sheet/sheet interface). [8]
resistance
welding which determines the heat generation by a
The thickness range is 0.7 4 mm. Fatigue properties in terms
power
of
square as shown in the formula. welding current
of Wohler curves and Fatigue strength at 2*106 cycles are
applied
in
resistance welding including the single phase
compared between the different joining methods using load
alternating
current
(AC) that is still the most used in production,
transfer capacity per unit length of the joints. Fatigue strength
the
three
phase
direct
current (DC), the condensator discharge
is shown to be independent of matrix strength for spot welded
(CD),
and
the
newly
developed
middle frequency inverter DC.
joints. Spot welded, laser welded and clinched joints show
similar fatigue properties for 1mm sheet joints. Adhesive Usually the root mean square (RMS) values of the welding
bonded joints are five-fold stronger and the weld bonded joints current are used in the machine parameter settings and the
show considerable scatter with a lower bound fatigue strength process controls. It is often the tedious job of the welding
between spot welded and adhesive bonded joints. [9]The size engineers to find the optimized welding current and time for
of 0.5 mm thin AISI 420 grade (0.29 % C) was selected for the each individual welding application.
(ii) Welding time
study and effect of welding current (W2) and post heating (W3)
The heat generation is directly proportional to the
on nugget dimension, tensile shear strength, cross tension
welding
time. Due to the heat transfer from the weld zone to
strength and hardness was studied and lobe diagram was
the
base
metals and to the electrodes, as well as the heat loss
generated for said material. Result shows very narrow lobe
width being 1.3 KA at 4 cycles and 0.7 KA at 7 cycles. It was from the free surfaces to the surroundings, a minimum welding
observed that effect of W2 and W3 variables is similar on current as well as a minimum welding time will be needed to
nugget diameter. Tensile-shear breaking load increases with make a weld. If the welding current is too low, simply
increase in weld current while cross-tension breaking load & increasing the welding time alone will not produce a weld.
ductility ratio decreases with increase in weld current. Post- When the welding current is high enough, the size of the weld
heat current leads to decrease in hardness with increase in nugget increases with increasing welding time until it reaches a
size similar to the electrode tip contact area. If the welding time
nugget diameter [10]
is prolonged, expulsion will occur or in the worst cases the
Although resistance spot welding are widely used it is electrode may stick to the work piece.
difficult to ensure the consistency of joint quality in weld
(iii) Welding force
production. The confidence level of the weld is achieved by the
If the welding force is too low, expulsion may occur
peel of test is low due to their shortcomings such as offline and
immediately after starting the welding current due to fact that
small sample to reduce the part failure manufacturers have to
the contact resistance is too high, resulting in rapid heat
extra more weld than the originally designed weld. It is
generation. If the welding force is high, the contact area will be
desirable to control weld quality immediately by adjusting the9257
Journal
of Applied
Engineering
Research ISSN 0973-4562
Volume
10, Number
6
8
9 9 (2015)
7
large resulting in lowInternational
current density
and
low contact
resistance
Research
India nugget.
Publications
7
8
9
8
that will reduce heat generation and the
size of weld
In ::: http://www.ripublication.com
8
8
7
9
projection welding, the welding force causes the collapse of the
9
8
8
9
projection in the workpiece, which changes the contact area
10
7
8
8
and thereby the contact resistance and the current density. It
11
7
8
7
further influences the heat development and the welding results.
12
7
7
7
(iv) Contact resistance
13
7
9
7
The contact resistance at the weld interface is the most
14
7
8
9
influential parameter related to materials. It however has highly
15
7
7
9
dynamic interaction with the process parameters. It is noticed
16
7
7
8
that the contact resistance generally decreases with increasing
17
7
9
8
temperature but has a local ridge around 300C, and it
18
7
9
9
decreases almost proportionally with increasing pressure.
19
6
9
9
20
21
22
23
24
25
26
27
Electrode
diameter
(mm)
Welding
current(
KA)
1
2
3
4
5
8
8
8
8
8
7
8
7
8
9
Heat
ing
time(
Ms)
7
7
8
8
9
6
6
6
6
6
6
6
6
9
8
7
7
9
8
7
8
Table 1
Welding Parameters
III. ASSESSME
IV. NT OF MECHANICAL PROPERTIES
The basic idea of a tensile test is to place a sample of a
material between two fixtures called grips 8m, which clamp the
material. The material has known dimensions, like length and crosssectional area. We then begin to apply weight to the material
gripped at one end while the other end is fixed. We keep increasing
the weight (often called the load or force) while at the same time
measuring the change in length of the sample.
A. Tensile tests
The basic idea of a tensile test is to place a sample of a
material between two fixtures called grips 8m, which clamp the
material. The material has known dimensions, like length and crosssectional area. We then begin to apply weight to the material
gripped at one end while the other end is fixed. We keep increasing
the weight (often called the load or force) while at the same time
measuring the change in length of the sample.
This creates what material scientists refer to as engineering
stress (load divided by the initial cross-sectional area) and
engineering strain (displacement divided by initial length). By
looking at the engineering stress-strain response of a material we
can compare the strength of different materials, independently of
their sizes
force(N)
12300
14700
14500
17200
18000
7
9
8
7
8
8
9
7
16000
16700
14800
15700
14500
13700
13300
15800
15900
14100
13500
18100
19200
17400
16400
16200
13500
13900
18100
15700
14200
14400
Fig 2
before tensile test
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International
of Applied
Research ISSN 0973-4562 Volume 10,
9 (2015)
After involve in the
welding Journal
the character
of Engineering
the component
IVNumber
RESULTS
Research India Publications ::: http://www.ripublication.com
has been changed that has shown by pictures
Spec
Diamet
current
Heating
Force
Ultimate
imen
er
(kA)
time
(N)
tensile
No
(mm)
(ms)
strength
(Mpa)
Fig 3
after tensile test
B.Metallurgical properties
Microstructure can also be used as a special tool to
predict tool life or to predict performance of a specific part. It
can also be used as an inspection tool to examine the quality of
a heat treatment or a raw material supplier.
18000
360
18
19200
385
24
18100
362
9259
Load
Of Spot
Welds Of
Duplex10,Stainless
Steel
2205 Grade,Mechanica Confab
International
Journal of Applied Engineering Research
ISSN
0973-4562
Volume
Number
9 (2015)
V.CONCLUSION
ISSN:
2320-2491
Research
India
Publications
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Observing above graphs we conclude that effect of current is
[4] Ajitanshu Vedrtnam , Gyanendra Singh Study Of Effect Of Parameters
predominant as compared to heating time in the context of heat On Resistance Spot Weld Of Stainless Steel Material International Journal of
input, which in turn affects strength of weld and loading which Engineering Research & Technology (IJERT) Vol. 2 Issue 7, July 2013 ISSN:
it can sustain. Also the effect of diameter shows that reduction 2278-0181
Jianhui Xu,Xiuping Jiang,Qiang Zeng Optimization Of Resistance Spot
in diameter imparts concentrated energy input eg: 6mm [5]
Welding On The Assembly Of Refractory Alloy 50mo50re Thin Sheet
compared to 8mm. This shows that weld nugget formed using Journal of nuclear materials 366(2007) 417-425
6mm diameter electrode is stronger than that of 8mm diameter [6] A.Aravinthan and C. Nachimani, Analysis of Spot Weld Growth on Mild
electrode. Thus varying the parameters we have find the and Stainless Steel,Nugget growth by varying current and weld time was
analyzed in joining mild steel, austenitic stainless steel, and dissimilar steels
suitable weld holding the maximum with stand able limit.
Sponsored by the American Welding Society and the Welding Research
Council, August 2011
[7] Wei LIU1)y, Jun HE1), Meng FAN1), Peide LU2) and Li Deformation at
Room and Low Temperatures and Martensite Transformation in Resistance
Spot Welding Duplex & () Materials of 301L Stainless Steel SHAO2) J.
Mater. Sci. Technol., Vol.23 No.3, August 22, 2006
[8] M. Pouranvari and s. P. H. Marashi Failure Mode Transition in AISI 304
Resistance Spot Welds, November 2012, VOL. 91 Welding Journal
[9] Hans Nordberg Fatigue Properties of Stainless Steel Lap Joints. Spot
welded, adhesive bonded, weld bonded, laser welded and clinched joints of
REFERENCES
stainless steel sheets-a review of their fatigue properties. Outokumpu Stainless
[1] L. D. Connell Johnson Joining Stainless Steel by Soldering, Brazing and
Research Foundation and Sheffield Hallam University 2005-01
Resistance Welding, Matthey Metals Limited, London Reprinted from
[10] S .K .Agrawal and Nandish Shroff Vishvesh J Badheka Resistance
Stainless Steel Industry, January 2005
Spot Welding Of Martensitic Stainless Steel (Ss420) - Part I , International
[2] A. Subrammanian , D.B. Jabaraj Research on Resistance Spot Welding
Journal of Mechanical and Materials Engineering (IJMME), Vol. 4 (2009), No.
of Stainless Steel - An Overview International Journal of Scientific &
3, 328-340
Engineering Research, Volume 4, Issue 12, December-2013 1741 ISSN 22295518 IJSER 2013
.
[3] D.S. Sahota, Ramandeep Singh, Rajesh Sharma, Harpreet Singh, D.S.
Sahota et aStudy And Analysis Of Welding Process Parameters On Failure
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