Resistance spot welding is a process commonly used for joining a stack of two or three metal sheets at desired spots. Such welds are accomplished by holding the metallic workpieces together by applying pressure through the tips of a pair of electrode...
This paper investigated various aspects of replacing existing micro-resistance spot welding (micro-RSW) with micro-laser spot welding for joining Inconel 718 thin foils to thick 410 steel stack-up to allow faster, non-contact joining together with fl...
For several decades, the electrical resistance spot welding process has been widely used in the manufacturing of sheet metal structures, especially in automotive bodies. During this period there was no significant development for this welding process...
Conventional resistance spot welds are not visible from the outside. Therefore, it is not straightforward to evaluate the joint quality non-destructively. The pulse-echo method of manual ultrasonic is widely used for non-destructive testing. Another...
The manufacture of complicated automobile components that are joined by resistance spot welding requires considerable cost and time. The use of additive manufacturing technology to manufacture automobile components helps reduce the overall time consu...
Paint-free bodywork has become an attractive alternative for rail vehicles, in the direction of easy maintainability and low manufacturing costs. However, conventional resistance spot welding inevitably leaves indentation marks to detrimentally reduc...
This work aims at investigating the spot weldability of a new advanced Quenching and Partitioning (Q&P) steel and a Transformation Induced Plasticity (TRIP) steel for automotive applications by evaluating the effects of the main welding parameter...
An efficient nondestructive testing method of resistance spot weld quality is essential in evaluating the weld quality of all welded joints in the automotive components of a car body production line. This study proposes a quality prediction algorithm...
To tackle the development of large-capacity titanium shell batteries, resistance spot welding was performed to join 1 mm thick TA2 titanium plate and T2 copper plate with a tungsten electrode on the copper side and a CuCrZr alloy electrode on the tit...
Resistance spot welding (RSW) is one of the most effective welding methods for titanium alloys, in particular Ti-6Al-4V. Ti-6Al-4V is one of the most used materials with its good ductility, high strength, weldability, corrosion resistance, and heat r...
Electrodes for resistance spot welding inevitably wear out. In order to extend their service life, the tip-dressing process restores their original geometry. So far, however, the point in time for tip-dressing is mainly based on experience and not on...
In a car body, there exist thousands of resistance spot welds, which may induce large deformation during the manufacturing process. Therefore, it is expected that automotive industries will develop a method and a computing system for the fast and sim...
Resistance spot welding of aluminum (Al5754) to magnesium (AZ31B) alloys results in the formation of a variety of solidification microstructures and intermetallic compounds that may affect the in-service performance of the weld. This study evaluates...
Metal–plastic composites (MPCs) are gaining importance mainly due to high strength to weight ratio. They consist of three layers, two outer metallic cover sheets, and a plastic core. The presence of that inner plastic layer makes them rather unsuitab...
This work is aimed at the analysis of the dynamic resistance, electrical energy and behavior of the force between electrodes (including thermal expansion) during welding at optimized parameters, referring to the process of spot welding using additive...
During resistance spot welding, the welding current is the most important process parameter, which determines the welding heat input and then has a great influence on the welding quality. In present study, the CR590T/340YDP galvanized dual phase stee...
The quality of the resistance spot weld is predicted qualitatively using information from the weld’s external apparent image. The predicting tool used for weld qualities was a convolution neural network (CNN) algorithm with excellent performanc...
The design of most electric vehicles provides for the positioning of the heavy energy storage units in the underbody of the cars. In addition to crash safety, the battery housing has to meet high requirements for gas tightness. In order to test the u...
The paper deals with the dynamics of a resistance spot welding system. At the core of this system is a transformer, which is powered on the primary side by a pulse-width modulated inverter and has a full-wave output rectifier on the secondary side th...
The aim of this investigation is to offer a data-based scheme for predicting electrode wear in resistance spot welding. One of the major factors affecting the mechanical properties of spot welds and the variation in weld quality is electrode wear and...
Real-time detection of welding defects in resistance spot welding is a complex challenge. Dynamic resistance (DR) reflects nugget growth and varies with defect types, serving as a key indicator. This study presents an online quality evaluation and de...
Resistance spot welding is a process with high variability regarding the quality of the produced joints. This means that key performance indicators (KPIs) such as geometrical and mechanical features as well as failure modes can deviate from the initi...
Resistance spot-welding of dissimilar metals, medium manganese TRIP steel 7Mn and DP590, is carried out. The effects of single-pulse welding parameters and a double-pulse-tempering current on the quality characteristic parameters and mechanical prope...
In resistance spot welding (RSW), the total electrical resistance (dynamic resistance) as the sum of bulk and contact resistance is a key variable. Both of these respective resistances influence the welding result, but the exact ratio to the total re...
Resistance spot welding was performed to join a 2 mm thick TA2 titanium plate and Q235 steel plate using nickel foil with thicknesses of 0.02 mm, 0.04 mm, and 0.06 mm as interlayers. The microstructure of the nugget zone and the interface region of t...
In recent years, the use of aluminum alloys in the automotive industry has been increasingly promoted to achieve lightweight vehicle bodies. Meanwhile, resistance spot welding (RSW) has long been widely employed for automotive body assembly, and thus...
Although resistance spot welding (RSW) was invented at the beginning of the last century, the online-monitoring and control of RSW is still a technological challenge and of economic and ecological importance. Process, material and geometry parameters...
Resistance spot welding is widely adopted in manufacturing and is characterized by high reliability and simple automation in the production line. The detection of defective welds is a difficult task that requires either destructive or expensive and s...
Micro resistance spot welding (MRSW) is an important technology widely used in electronics manufacturing for micro component joining. For the joining of micro enameled wire, quality control is heavily dependent on manual inspection till now. In this...
Double pulse resistance spot welding process by applying a second step welding current is a new pathway to alter the mechanical properties for advanced high strength steels. Herein, the resistance spot welding (RSW) of hot stamped boron steel 15B22 b...
Resistance spot welding was performed to join 2 mm thick TA2 titanium plate and Q235 steel plate using an Nb-Ni bi-interlayer. The microstructure of the interfacial zone was observed and analyzed, and the tensile shear load of the joint was evaluated...
In a small sample welding test space, and to achieve online prediction and self-optimisation of process parameters for the resistance welding joint quality of power lithium battery packs, this paper proposes a welding quality prediction model. The mo...
Although short-pitch resistance spot welding (RSW) significantly increases vehicle body strength, its application has been limited because of the associated shunting effect. In this study, a reference-based adaptive RSW process intended to minimize t...
Rectangular terminal electrode is adopted in this research to conduct a resistance spot welding (RSW) process on stainless steel plate. The connection status of RSW joints under different welding current, time, and pressure were studied, and revealed...
In this paper, the impact of the winding arrangement on the efficiency of the resistance spot welding (RSW) transformer is presented. First, the design and operation of the transformer inside a high power RSW system are analyzed. Based on the present...
Resistance spot welding (RSW) is one of the dominant joining processes in body-in-white manufacturing within the automotive industry, while the use of aluminum alloys continues to increase. This study investigates the influence of key process paramet...
Resistance spot welding (RSW) faces critical monitoring challenges in industrial applications due to nonlinear coupling characteristics and production line disturbances. This study developed a Zigbee-enabled real-time monitoring system to address the...
Post-weld evaluation does not readily capture the dynamic evolution of nugget formation in resistance spot welding. In this study, an embedded ultrasonic probe was used to acquire A-scan signals during resistance spot welding of stainless steel. Cons...
Resistance spot welding poses potential challenges for automotive manufacturing enterprises with regard to ensuring the real-time and accurate quality detection of each welding spot. Nowadays, many machine learning and deep learning methods have been...
This paper presents an enhanced Faster R-CNN model for detecting surface defects in resistance welding spots, improving both efficiency and accuracy for body-in-white quality monitoring. Key innovations include using high-confidence anchor boxes from...
Finding a reliable quality inspection system of resistance spot welding (RSW) has become a very important issue in the automobile industry. In this study, improvement in the quality estimation of the weld nugget’s surface on the car underbody i...
The automotive industry is adopting the Industry 4.0 model to reduce failures in electrical resistance spot welding by using automated non-destructive testing systems. This study presents a real-time machine vision system that has been implemented on...
Reliable process monitoring and quality evaluation for resistance spot welding (RSW) have become more important now than ever. An ultrasonic probe embedded into welding electrodes has enabled the acquisition of data about molten pool formation throug...
The resistance spot welding (RSW) process is still widely used to weld panels and bodies, particularly in the automotive, railroad, and aerospace industries. The purpose of this research is to examine how RSW factors such as welding current, welding...
Resistance spot welding (RSW) with inserted strips, a recent variant of traditional RSW, was usually adopted in joining thin gage steels to lower the temperature developed at the electrode surface and to extend electrode life. In order to understand...
The automobile industry relies primarily on spot welding operations, particularly resistance spot welding (RSW). The performance and durability of the resistance spot-welded joints are significantly impacted by the welding quality outputs, such as th...
The current nondestructive testing methods such as ultrasonic, magnetic, or eddy current signals, and even the existing image processing methods, present certain challenges and show a lack of flexibility in building an effective and real-time quality...
In this study, the effects of electrical characteristics of an inverter combined with main welding parameters on the resistance spot weldability of advanced high strength steels (AHSS) CP1000 is investigated. The main welding parameters, current and...
Joining of stainless steel to carbon steel is widely used in various industries. Resistance spot welding (RSW) is a suitable process for joining steel sheets. Due to the complexity and importance of optimizing the parameters, numerical simulation of...
In recent years, increasing automotive safety by improving crashworthiness has been a focal point in the automotive industry, employing high-strength steel such as press hardenable steel (PHS). In addition to the improved strength of individual parts...
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