Research on the Improvement of Weldability in Resistance Spot Welding of 6-Series Aluminum Alloys

Lihui Zhong; Yuanbo Guo; Suhong Ji; Lijun Han

doi:doi:10.11648/j.ijmea.20231105.12

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Research on the Improvement of Weldability in Resistance Spot Welding of 6-Series Aluminum Alloys

Lihui Zhong^*, Yuanbo Guo, Suhong Ji, Lijun Han

Published in International Journal of Mechanical Engineering and Applications (Volume 11, Issue 5)

Received: 12 October 2023 Accepted: 8 November 2023 Published: 30 November 2023

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Abstract

Aluminum alloy RSW is influenced by the low melting point and high thermal expansion rate of aluminum alloy materials. During the welding process, the electrode cap surface is prone to erosion, which affects the continuous welding number and welding quality of RSW. It is a difficult problem in the industry that restricts the application of aluminum RSW. This article studies the factors affecting the weldability of resistance spot welding (RSW) of aluminum alloy materials, including plate materials, electrode specifications and materials, equipment structure and welding control methods, electrode connection methods, welding process specifications, etc., and identified possible ways to enhance the weldability and weld quality of aluminum alloy spot welding. Through the experimental study, it was further explored that the comprehensive performance capability of aluminum alloy RSW can be improved by setting appropriate welding parameters for the electrode with R100mm arc at the front end for the flat aluminum plate which has been pickled and passivated.

Published in	International Journal of Mechanical Engineering and Applications (Volume 11, Issue 5)
DOI	10.11648/j.ijmea.20231105.12
Page(s)	113-124
Creative Commons	This is an Open Access article, distributed under the terms of the Creative Commons Attribution 4.0 International License (http://creativecommons.org/licenses/by/4.0/), which permits unrestricted use, distribution and reproduction in any medium or format, provided the original work is properly cited.
Copyright	Copyright © The Author(s), 2024. Published by Science Publishing Group

Keywords

Al Alloy RSW, Electrode, Surface Erosion, Welding Parameters, Welding Nugget, Peltier Effect

References

[1]	P Shan, et al. Reconstruction of Current Density Distribution in Weld Area During Resistance Spot Welding of Al. Alloy Based on Magnetic Field. Transactions of Tianjin University 21.02 (2015): 129-134.
[2]	A K Deepati, et al. Mechanical characterization of A5083 Al alloy welded using resistance RSW for the lightweight automobile body fabrication [J]. Materials Today: Proceedings 2021, 45: 5139-5148.
[3]	M Zhang, et al. Study of electrode tip morphology on the performance in resistance RSW of AA5182 Al alloy [J]. Transactions of the China Welding Institution, 2018, 39 (4): 84−88.
[4]	B Wang, et al. Effects of electrode tip morphology on resistance RSW quality of DP590 dual-phase steel [J]. The International Journal of Advanced Manufacturing Technology, 2016, 83 (9): 1917−1926.
[5]	D Q Sun, et al. Effects of electrode morphology on microstructures and mechanical properties of spot welded Al-steel joints [J]. Journal of Mechanical Engineering, 2016, 52 (24): 36−43.
[6]	Yuan Bo Research on Resistance Spot Welding Technology of Aluminum Alloy for Vehicle Body [D]. Hefei University of Technology, 2020. DOI: 10.27101/d.cnki.ghfgu.2019.000344.
[7]	Yu Hui, et al. The Study on the Ineffective Mechanism of Aluminum Alloy Spot Welding Electrode, Journal \| [J] Key Engineering Materials. Volume 531-532, Issue 531-532. 2012. PP 84-87.
[8]	C. Ren, et al. Effect of bake hardening treatment on the mechanical behaviors of aluminum alloy spot welding joints, Journal \| [J] Russian Journal of Non-Ferrous Metals. Volume 58, Issue 5. 2017. PP 500-508.
[9]	Jidong Kang, et al. Fatigue Behavior of Dissimilar Aluminum Alloy Spot Welds. Journal \| [J]. Procedia Engineering. Volume 114, Issue. 2015. PP 149-156.
[10]	D. Han. et al. Study on asymmetric thermo-physical effect mechanism of intermediate frequency DC resistance spot welding for aluminum alloy [J]. China Welding, 2021, 30 (01): 48-56.
[11]	Egolf P W, et al. High-frequency magnetocaloric modules with heat gates operating with the Peltier effect. International Journal of Refrigeration, 2014, 37: 176-186. DOI: 10.1016/j.ijrefrig.2013.09.028.
[12]	Astrain D, et al. Computational model for refrigerators based on Peltier effect application. Applied Thermal Engineering, 2005, 25 (17): 3149-3162 DOI: 10.1016/j.applthermaleng.2005.04.003.
[13]	Yang Li, et al. Weld growth mechanisms and failure behavior of three-sheet resistance spot welds made of 5052 Al alloy. Journal of materials engineering and performance, 2015, 24: 2546–2555. DOI: 10.1007/s11665–0 15-1519-9.
[14]	Drebushchak V. A. The Peltier Effect. J. Therm. Anal. Calorim, 2008, 91 (1): 311–315.
[15]	Zhang Y Y, Sun D Q. Effect of electrode morphology on steel /Al alloy joint. China Welding, 2019, 28 (01): 16-27.

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APA Style

Zhong, L., Guo, Y., Ji, S., Han, L. (2023). Research on the Improvement of Weldability in Resistance Spot Welding of 6-Series Aluminum Alloys. International Journal of Mechanical Engineering and Applications, 11(5), 113-124. https://doi.org/10.11648/j.ijmea.20231105.12

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ACS Style

Zhong, L.; Guo, Y.; Ji, S.; Han, L. Research on the Improvement of Weldability in Resistance Spot Welding of 6-Series Aluminum Alloys. Int. J. Mech. Eng. Appl. 2023, 11(5), 113-124. doi: 10.11648/j.ijmea.20231105.12

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AMA Style

Zhong L, Guo Y, Ji S, Han L. Research on the Improvement of Weldability in Resistance Spot Welding of 6-Series Aluminum Alloys. Int J Mech Eng Appl. 2023;11(5):113-124. doi: 10.11648/j.ijmea.20231105.12

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@article{10.11648/j.ijmea.20231105.12,
  author = {Lihui Zhong and Yuanbo Guo and Suhong Ji and Lijun Han},
  title = {Research on the Improvement of Weldability in Resistance Spot Welding of 6-Series Aluminum Alloys},
  journal = {International Journal of Mechanical Engineering and Applications},
  volume = {11},
  number = {5},
  pages = {113-124},
  doi = {10.11648/j.ijmea.20231105.12},
  url = {https://doi.org/10.11648/j.ijmea.20231105.12},
  eprint = {https://article.sciencepublishinggroup.com/pdf/10.11648.j.ijmea.20231105.12},
  abstract = {Aluminum alloy RSW is influenced by the low melting point and high thermal expansion rate of aluminum alloy materials. During the welding process, the electrode cap surface is prone to erosion, which affects the continuous welding number and welding quality of RSW. It is a difficult problem in the industry that restricts the application of aluminum RSW. This article studies the factors affecting the weldability of resistance spot welding (RSW) of aluminum alloy materials, including plate materials, electrode specifications and materials, equipment structure and welding control methods, electrode connection methods, welding process specifications, etc., and identified possible ways to enhance the weldability and weld quality of aluminum alloy spot welding. Through the experimental study, it was further explored that the comprehensive performance capability of aluminum alloy RSW can be improved by setting appropriate welding parameters for the electrode with R100mm arc at the front end for the flat aluminum plate which has been pickled and passivated.
},
 year = {2023}
}

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TY  - JOUR
T1  - Research on the Improvement of Weldability in Resistance Spot Welding of 6-Series Aluminum Alloys
AU  - Lihui Zhong
AU  - Yuanbo Guo
AU  - Suhong Ji
AU  - Lijun Han
Y1  - 2023/11/30
PY  - 2023
N1  - https://doi.org/10.11648/j.ijmea.20231105.12
DO  - 10.11648/j.ijmea.20231105.12
T2  - International Journal of Mechanical Engineering and Applications
JF  - International Journal of Mechanical Engineering and Applications
JO  - International Journal of Mechanical Engineering and Applications
SP  - 113
EP  - 124
PB  - Science Publishing Group
SN  - 2330-0248
UR  - https://doi.org/10.11648/j.ijmea.20231105.12
AB  - Aluminum alloy RSW is influenced by the low melting point and high thermal expansion rate of aluminum alloy materials. During the welding process, the electrode cap surface is prone to erosion, which affects the continuous welding number and welding quality of RSW. It is a difficult problem in the industry that restricts the application of aluminum RSW. This article studies the factors affecting the weldability of resistance spot welding (RSW) of aluminum alloy materials, including plate materials, electrode specifications and materials, equipment structure and welding control methods, electrode connection methods, welding process specifications, etc., and identified possible ways to enhance the weldability and weld quality of aluminum alloy spot welding. Through the experimental study, it was further explored that the comprehensive performance capability of aluminum alloy RSW can be improved by setting appropriate welding parameters for the electrode with R100mm arc at the front end for the flat aluminum plate which has been pickled and passivated.

VL  - 11
IS  - 5
ER  -

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Author Information

Lihui Zhong

FAW-Volkswagen Automotive Company, Ltd., Changchun, China

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Yuanbo Guo

FAW-Volkswagen Automotive Company, Ltd., Changchun, China

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Suhong Ji

Volkswagen (Anhui) Automotive Company, Ltd., Hefei, China

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Lijun Han

FAW-Volkswagen Automotive Company, Ltd., Changchun, China

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Plain Text BibTeX RIS

APA Style

Zhong, L., Guo, Y., Ji, S., Han, L. (2023). Research on the Improvement of Weldability in Resistance Spot Welding of 6-Series Aluminum Alloys. International Journal of Mechanical Engineering and Applications, 11(5), 113-124. https://doi.org/10.11648/j.ijmea.20231105.12

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ACS Style

Zhong, L.; Guo, Y.; Ji, S.; Han, L. Research on the Improvement of Weldability in Resistance Spot Welding of 6-Series Aluminum Alloys. Int. J. Mech. Eng. Appl. 2023, 11(5), 113-124. doi: 10.11648/j.ijmea.20231105.12

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AMA Style

Zhong L, Guo Y, Ji S, Han L. Research on the Improvement of Weldability in Resistance Spot Welding of 6-Series Aluminum Alloys. Int J Mech Eng Appl. 2023;11(5):113-124. doi: 10.11648/j.ijmea.20231105.12

Copy | Download

@article{10.11648/j.ijmea.20231105.12,
  author = {Lihui Zhong and Yuanbo Guo and Suhong Ji and Lijun Han},
  title = {Research on the Improvement of Weldability in Resistance Spot Welding of 6-Series Aluminum Alloys},
  journal = {International Journal of Mechanical Engineering and Applications},
  volume = {11},
  number = {5},
  pages = {113-124},
  doi = {10.11648/j.ijmea.20231105.12},
  url = {https://doi.org/10.11648/j.ijmea.20231105.12},
  eprint = {https://article.sciencepublishinggroup.com/pdf/10.11648.j.ijmea.20231105.12},
  abstract = {Aluminum alloy RSW is influenced by the low melting point and high thermal expansion rate of aluminum alloy materials. During the welding process, the electrode cap surface is prone to erosion, which affects the continuous welding number and welding quality of RSW. It is a difficult problem in the industry that restricts the application of aluminum RSW. This article studies the factors affecting the weldability of resistance spot welding (RSW) of aluminum alloy materials, including plate materials, electrode specifications and materials, equipment structure and welding control methods, electrode connection methods, welding process specifications, etc., and identified possible ways to enhance the weldability and weld quality of aluminum alloy spot welding. Through the experimental study, it was further explored that the comprehensive performance capability of aluminum alloy RSW can be improved by setting appropriate welding parameters for the electrode with R100mm arc at the front end for the flat aluminum plate which has been pickled and passivated.
},
 year = {2023}
}

Copy | Download

TY  - JOUR
T1  - Research on the Improvement of Weldability in Resistance Spot Welding of 6-Series Aluminum Alloys
AU  - Lihui Zhong
AU  - Yuanbo Guo
AU  - Suhong Ji
AU  - Lijun Han
Y1  - 2023/11/30
PY  - 2023
N1  - https://doi.org/10.11648/j.ijmea.20231105.12
DO  - 10.11648/j.ijmea.20231105.12
T2  - International Journal of Mechanical Engineering and Applications
JF  - International Journal of Mechanical Engineering and Applications
JO  - International Journal of Mechanical Engineering and Applications
SP  - 113
EP  - 124
PB  - Science Publishing Group
SN  - 2330-0248
UR  - https://doi.org/10.11648/j.ijmea.20231105.12
AB  - Aluminum alloy RSW is influenced by the low melting point and high thermal expansion rate of aluminum alloy materials. During the welding process, the electrode cap surface is prone to erosion, which affects the continuous welding number and welding quality of RSW. It is a difficult problem in the industry that restricts the application of aluminum RSW. This article studies the factors affecting the weldability of resistance spot welding (RSW) of aluminum alloy materials, including plate materials, electrode specifications and materials, equipment structure and welding control methods, electrode connection methods, welding process specifications, etc., and identified possible ways to enhance the weldability and weld quality of aluminum alloy spot welding. Through the experimental study, it was further explored that the comprehensive performance capability of aluminum alloy RSW can be improved by setting appropriate welding parameters for the electrode with R100mm arc at the front end for the flat aluminum plate which has been pickled and passivated.

VL  - 11
IS  - 5
ER  -

Copy | Download