Numerical simulation strategies and test setup for resistance spot welding process with motion overlay

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• 作者：Stefan Heilmann ; Christian Mathiszik ; Marcel Merx ; Jens Müller…
• 关键词：Aluminium alloys ; Resistance spot welding ; Resistance welding electrodes ; Contact resistance ; Simulating
• 刊名：Welding in the World
• 出版年：2017
• 出版时间：January 2017
• 年：2017
• 卷：61
• 期：1
• 页码：35-46
• 全文大小：
• 刊物主题：Metallic Materials; Continuum Mechanics and Mechanics of Materials; Theoretical and Applied Mechanics;
• 出版者：Springer Berlin Heidelberg
• ISSN：1878-6669
• 卷排序：61

文摘

The continuing trend of lightweight construction within the industry requires joining methods for lightweight materials, such as aluminium alloys, that provide a safe and reliable result. One of these processes is resistance spot welding. Its high level of automation and efficiency lead to being one of the most widely used joining methods. The current problem in resistance spot welding of aluminium alloys is the high wear of the electrodes. One reason is the insulating effect of the aluminium oxide layer. The high electrical resistance of the oxide results in local temperature rise and an increased wear on the electrodes. In the extreme, after less than 100 spot welds, the process reliability is no longer guaranteed. A way to reduce the wear is the mechanical destruction of the oxide layer. One possibility is to rotate the welding gun and thus the electrodes around the z-axis, as KUKA’s RoboSpin realizes it.