Abstract
Resistance spot welding (RSW) of aluminum–aluminum (Al–Al) is known to be very challenging, with the asymmetric growth of the weld nugget often observed. In this article, a semicoupled electrical–thermal–mechanical finite element analysis (FEA) procedure was established to simulate the RSW of two layers of AA6022-T4 sheets using a specially designed Multi-Ring Domed (MRD) electrodes. Critical to the modeling procedure was the thermoelectric (including the Peltier, Thomson, and Seebeck effects) analyses to simulate the asymmetric nugget growth in the welding stage. Key input parameters such as the Seebeck coefficients and high-temperature flow stress curves were measured. Simulation results, experimentally validated, indicated that the newly developed procedure could successfully predict the asymmetric weld nugget growth. Simulation results also showed the Seebeck effect in the holding stage. The simulations represent the first quantitative investigation of the impact of the thermoelectric effects on resistance spot welding.
References
1.
Cai
, W.
, Daehn
, G.
, Vivek
, A.
, Li
, J.
, Khan
, H.
, Mishra
, R. S.
, and Komarasamy
, M.
, 2019
, “A State-of-the-Art Review on Solid-State Metal Joining
,” ASME J. Manuf. Sci. Eng.
, 141
(3
), p. 031012
. 10.1115/1.40411822.
Gould
, J.
, “Challenges and Advances in Resistance Spot Welding Aluminum Sheet
,” EWI Report, April 28, 2014.3.
Sigler
, D. R.
, Carlson
, B. E.
, and Janiak
, P.
, 2014
, “A Preliminary Assessment of GM’s Multi-Ring Domed (MRD) Electrode for Alternately Welding Aluminum-to-Aluminum and Steel-to-Steel Stack-ups
,” AWS Sheet Metal Welding Conference XVI
, AWS
, Livonia, MI
, Oct. 22–24
.4.
Rashid
, M.
, 2011
, “Some Tribological Influences on the Electrode-Worksheet Interface During Resistance Spot Welding of Aluminum Alloys
,” J. Mater. Eng. Perform.
, 20
(3
), pp. 456
–462
. 10.1007/s11665-010-9696-z5.
Sigler
, D. R.
, Carlson
, B. E.
, and Janiak
, P.
, 2013
, “Improving Aluminum Resistance Spot Welding in Automotive Structures
,” Weld. J.
, 92
(6
), pp. 64
–72
.6.
Sigler
, D. R.
, and Carlson
, B. E.
, 2012
, “Aluminum Resistance Spot Welding Electrode Degradation
,” AWS Sheet Metal Welding Conference XV
, Livonia, MI
, Oct. 2–5
.7.
Sigler
, D. R.
, Schroth
, J. G.
, Karagoulis
, M. J.
, and Zuo
, D.
, 2010
, “New Electrode Weld Face Geometries for Spot Welding Aluminum
,” AWS Sheet Metal Welding Conference XIV
, Livonia, MI
, May 11–14
, pp. 11
–14
.8.
Deng
, L.
, Li
, Y. B.
, Carlson
, B. E.
, and Sigler
, D. R.
, 2018
, “Effects of Electrode Surface Topography on Aluminum Resistance Spot Welding
,” Weld. J.
, 97
(4
), pp. 120
–132
. 10.29391/2018.97.0119.
Sigler
, D. R.
, and Karagoulis
, M. J.
, 2018
, “Weld Schedule for Resistance Spot Welding of Aluminum Alloy Workpieces
,” US Patent No. 9,969,026.10.
Balder
, T. C.
, 1959
, “Influence of the Peltier Effect in Resistance Welding
,” Philips Tech. Rev.
, 20
, pp. 188
–192
.11.
Hasir
, M. A.
, 1984
, “Study of the Peltier Effect in the Resistance Spot Welding of Very Thin-Gauge Sheet Electroplated With Tin Using Tungsten-Insert Electrodes
,” Weld. Cutting
, 36
(3
), pp. 116
–121
.12.
Knorovsky
, G. A.
, 1991
, Overlooked Fundamentals of Resistance Welding (No. SAND-91-1756C; CONF-911003-15)
, Sandia National Laboratories
, Albuquerque, NM
.13.
Zhou
, Y.
, Dong
, S. J.
, and Ely
, K. J.
, 2001
, “Weldability of Thin Sheet Metals by Small-Scale Resistance Spot Welding Using High-Frequency Inverter and Capacitor-Discharge Power Supplies
,” J. Electron. Mater.
, 30
(8
), pp. 1012
–1020
. 10.1007/BF0265772614.
Peng
, J.
, Fukumoto
, S.
, Brown
, L.
, and Zhou
, N.
, 2004
, “Image Analysis of Electrode Degradation in Resistance Spot Welding of Aluminum
,” Sci. Technol. Weld. Joining
, 9
(4
), pp. 331
–336
. 10.1179/13621710422501225615.
Li
, Y.
, Yan
, F.
, Luo
, Z.
, Chao
, Y. J.
, Ao
, S.
, and Cui
, X.
, 2015
, “Weld Growth Mechanisms and Failure Behavior of Three-Sheet Resistance Spot Welds Made of 5052 Aluminum Alloy
,” J. Mater. Eng. Perform.
, 24
(6
), pp. 2546
–2555
. 10.1007/s11665-015-1519-916.
Khan
, J. A.
, Xu
, L.
, and Chao
, Y. J.
, 1999
, “Prediction of Nugget Development During Resistance Spot Welding Using Coupled Thermal–Electrical–Mechanical Model
,” Sci. Technol. Weld. Joining
, 4
(4
), pp. 201
–207
. 10.1179/13621719910153778917.
Li
, Y. B.
, Lin
, Z. Q.
, Hu
, S. J.
, and Chen
, G. L.
, 2007
, “Numerical Analysis of Magnetic Fluid Dynamics Behaviors During Resistance Spot Welding
,” J. Appl. Phys.
, 101
(5
), p. 053506
. 10.1063/1.247227918.
Li
, Y. B.
, Lin
, Z. Q.
, Shen
, Q.
, and Lai
, X. M.
, 2011
, “Numerical Analysis of Transport Phenomena in Resistance Spot Welding Process
,” ASME J. Manuf. Sci. Eng.
, 133
(3
), p. 031019
. 10.1115/1.400431919.
Wintjes
, E.
, DiGiovanni
, C.
, He
, L.
, Bag
, S.
, Goodwin
, F.
, Biro
, E.
, and Zhou
, Y.
, 2019
, “Effect of Multiple Pulse Resistance Spot Welding Schedules on Liquid Metal Embrittlement Severity
,” ASME J. Manuf. Sci. Eng.
, 141
(10
), p. 101001
. 10.1115/1.404409920.
Browne
, D. J.
, Chandler
, H. W.
, Evans
, J. T.
, and Wen
, J.
, 1995
, “Computer Simulation of Resistance Spot Welding in Aluminum: Part 1
,” Weld. J.
, 74
(10
), pp. 339
–344
.21.
Xu
, L.
, and Khan
, J. A.
, 1999
, “Nugget Growth Model for Aluminum Alloys During Resistance Spot Welding
,” Weld. J.
, 78
(11
), pp. 367
–372
.22.
Sun
, X.
, and Dong
, P.
, 2000
, “Analysis of Aluminum Resistance Spot Welding Processes Using Coupled Finite Element Procedures
,” Weld. J.
, 79
(8
), pp. 215s
–221
.23.
Mo
, B. H.
, Zhang
, X. F.
, Wu
, J. Q.
, and Guo
, Z. N.
, 2012
, “Numerical Simulation on the Temperature Distribution in Resistance Microwelding of Insulated Cu Wire
,” Advanced Materials Research
, 472–475
, pp. 1143
–1146
.24.
Landau
, L. D.
, and Lifshitz
, E. M.
, 1984
, Electrodynamics of Continuous Media
, 2nd ed., Butterworth-Heinemann
, Oxford
.25.
Zhang
, W.
, and Bay
, N.
, 1998
, “Finite Element Modeling Aided Process Design in Resistance Welding
,” Eighth International Conference of Computer Technology in Welding
, Liverpool, UK
, June 22–24
, pp. 153
–163
.26.
James
, P. S.
, Chandler
, H. W.
, Evans
, J. T.
, Wen
, J.
, Browne
, D. J.
, and Newton
, C. J.
, 1997
, “The Effect of Mechanical Loading on the Contact Resistance of Coated Aluminum
,” Mater. Sci. Eng. A
, 230
(1–2
), pp. 194
–201
. 10.1016/S0921-5093(97)00020-827.
Wan
, Z.
, Wang
, H. P.
, Wang
, M.
, Carlson
, B. E.
, and Sigler
, D. R.
, 2016
, “Numerical Simulation of Resistance Spot Welding of Al To Zinc-Coated Steel With Improved Representation of Contact Interactions
,” Int. J. Heat Mass Transfer
, 101
, pp. 749
–763
. 10.1016/j.ijheatmasstransfer.2016.05.02328.
Huang
, H.
, Yin
, X.
, Feng
, Z.
, and Ma
, N.
, 2019
, “Finite Element Analysis and In-Situ Measurement of Out-of-Plane Distortion in Thin Plate TIG Welding
,” Materials
, 12
(1
), p. 141
. 10.3390/ma1201014129.
Brandt
, R.
, and Neuer
, G.
, 2007
, “Electrical Resistivity and Thermal Conductivity of Pure Aluminum and Aluminum Alloys up to and Above the Melting Temperature
,” Int. J. Thermophys.
, 28
(5
), pp. 1429
–1446
. 10.1007/s10765-006-0144-030.
Wang
, J.
, Wang
, H. P.
, Lu
, F.
, Carlson
, B. E.
, and Sigler
, D. R.
, 2015
, “Analysis of Al-Steel Resistance Spot Welding Process by Developing a Fully Coupled Multi-Physics Simulation Model
,” Int. J. Heat Mass Transfer
, 89
, pp. 1061
–1072
. 10.1016/j.ijheatmasstransfer.2015.05.08631.
Niedziolka
, K.
, Pothin
, R.
, Rouessac
, F.
, Ayral
, R. M.
, and Jund
, P.
, 2014
, “Theoretical and Experimental Search for ZnSb-Based Thermoelectric Materials
,” J. Phys. Condens. Matter
, 26
(36
), p. 365401
. 10.1088/0953-8984/26/36/36540132.
Fukumoto
, S.
, Lum
, I.
, Biro
, E.
, Boomer
, D. R.
, and Zhou
, Y.
, 2003
, “Effects of Electrode Degradation on Electrode Life in Resistance Spot Welding of Aluminum Alloy 5182
,” Weld. J.
, 82
(13
), pp. 307
–312
.33.
Lum
, I.
, Biro
, E.
, Zhou
, Y.
, Fukumoto
, S.
, and Boomer
, D. R.
, 2004
, “Electrode Pitting in Resistance Spot Welding of Aluminum Alloy 5182
,” Metall. Mater. Trans. A
, 35
(1
), pp. 217
–226
. 10.1007/s11661-004-0122-8Copyright © 2020 by General Motors
You do not currently have access to this content.
