New Technologies in Resistance Spot Welding

A special issue of Metals (ISSN 2075-4701). This special issue belongs to the section "Welding and Joining".

Deadline for manuscript submissions: closed (31 October 2023) | Viewed by 3163

Special Issue Editor


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Guest Editor
Department of Materials Science and Engineering, Sharif University of Technology, Tehran, Iran
Interests: welding of automotive materials; advanaced high strength steels; failure of welds; dissimilar welding; welding and joining of superalloys

Special Issue Information

Dear Colleagues,

Resistance spot welding still plays a critical role in automotive, aerospace, aero-engine, electrical, and other industries. In the automotive sector, various generations of advanced high-strength steels (AHSS) enabled engineers to design and manufacture weight-reduced automobiles with improved crash safety and fuel economy. However, the introduction of new advanced high-strength steels (e.g., TRIP steels, TWIP steels, QP steels, and Medium-Mn steels) in the automotive industry is accompanied by the challenge in their resistance spot weldability. The formation of brittle martensite in the weld, low-energy interfacial failure, heat-affected zone softening, and Zn-induced liquid–metal embrittlement are some of the critical welding challenges of advanced automotive steels. Moreover, the dissimilar joining of steel and low-density metals (i.e., Al and Mg) is also a key challenge for multi-materials lightweight design strategy in the automotive industry. The manufacturing of electric vehicles relies on applying a large amount of light Al alloys. In this case, the resistance spot weldability of Al alloys, as high-conductivity alloys, is a key challenge for EV manufacturing. In addition, joining plays a critical role in high-performance battery manufacturing, a crucial part of vehicle electrification. Resistance welding, as an easy, high-speed, and high-efficient joining process, is a candidate for welding in Li-Ion battery manufacturing. A thorough understanding of the process's physics, chemistry, and metallurgy is required to develop new technologies and innovations to solve the challenges faced in resistance spot welding.

In this Special Issue, we welcome reviews and research articles focusing on resistance spot welding challenges and opportunities in various industries, including automotive, aerospace, battery manufacturing, etc. We hope this Special Issue of Metals stimulates further invention and innovation in the field.

Dr. Majid Pouranvari
Guest Editor

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Keywords

  • resistance spot welding
  • automotive welding
  • battery welding
  • dissimilar welding
  • advanced high-strength steels
  • metallurgy
  • mechanical properties
  • failure

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Published Papers (1 paper)

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Research

15 pages, 4063 KiB  
Article
Quality Monitoring of Resistance Spot Welding Based on a Digital Twin
by Jianwei Dong, Jianming Hu and Zhen Luo
Metals 2023, 13(4), 697; https://doi.org/10.3390/met13040697 - 3 Apr 2023
Cited by 7 | Viewed by 2734
Abstract
As an important means to realize intelligent manufacturing, a digital twin is a digital expression of physical entities, which realizes virtual–real interaction and the iterative optimization of product design and manufacturing by constructing a bridge of information mapping between the physical world and [...] Read more.
As an important means to realize intelligent manufacturing, a digital twin is a digital expression of physical entities, which realizes virtual–real interaction and the iterative optimization of product design and manufacturing by constructing a bridge of information mapping between the physical world and the virtual world. Resistance spot welding technology is widely used in automotive manufacturing, aerospace and other fields as a spot linking process for the manufacture of thin sheet structures. The fusion nugget growth process of resistance spot welding is particularly important for its joint quality. Resistance spot welding is a highly nonlinear coupled process, and physical models make it difficult to accurately monitor its quality. Taking 2219/5A06 aluminum plates with different thicknesses as the research object, digital twin technology is applied to monitor the welding process of aluminum plate. In order to improve the key technologies such as information interaction in the digital twin system, a data acquisition system for resistance spot welding process is established and a real-time data processing technology based on wavelet threshold analysis is proposed. Based on real-time data, the processed process parameters are tested in twin space to validate the feasibility of the solution. Full article
(This article belongs to the Special Issue New Technologies in Resistance Spot Welding)
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