The book begins with thorough coverage of Resistance Spot Welding fundamentals and principles, including concepts such as Lobe Curves, contact resistance vs. electrode force, dynamic resistance, heat balance challenges, nugget growth, machine types and power supplies, and electrodes. Subsequent chapters address challenges and approaches to important topics of welding advanced high-strength steels, such as DP, TRIP, TWIP, and Press Hardening Steel, as well as aluminum alloys. Welding issues associated with the various coatings used on these steels are addressed. The final chapters are dedicated to weld quality, monitoring, testing, computational modeling, and common automotive production issues such as the welding of multiple sheet stack-ups and a brief overview of associated codes and standards. The second edition includes updated chapters and additional information, such as expanded information on welding aluminum to steel, a new section on alternative welding and joining methods, and updates on monitoring and control as well as welding issues associated with the latest advanced high-strength steels.
Author(s): Menachem Kimchi, David H. Phillips
Series: Synthesis Lectures on Welding Engineering
Edition: 2
Publisher: Springer
Year: 2023
Language: English
Pages: 124
City: Cham
Preface
Contents
About the Author
1 Introduction to Resistance Spot Welding
2 Resistance Spot Welding Process Physics and Fundamentals
2.1 Mechanism of Heat Generation and Nugget Growth
2.2 Effect of Electrode Force on Contact Resistance
2.3 Current Range and Lobe Curves
2.4 Expulsion
2.5 Determination of Spot Welding Parameters for Production
2.6 Dynamic Resistance
2.7 Heat Balance
3 Resistance Spot Welding Machines, Electrodes, and Tooling
3.1 Machine Types
3.2 Power Supplies
3.3 Electrode Materials
3.4 Electrode Geometries
4 Resistance Spot Welding of Modern Steels
4.1 Introduction to Automotive Steels
4.2 Conventional Steels
4.3 Welding of Conventional Uncoated Steels
4.4 Advanced High-Strength Steels
4.4.1 Transformation-Induced Plasticity (TRIP) Steels
4.4.2 Dual Phase (DP) Steels
4.4.3 Complex Phase (CP) Steels
4.4.4 Martensitic (MS) Steels
4.4.5 Twinning-Induced Plasticity (TWIP) Steels
4.4.6 Press Hardening Steels (PHS)
4.4.7 Ferritic-Bainitic (FB) Steels
4.5 Welding of Advanced High-Strength Steels
4.5.1 Spot Welding Parameters
4.5.2 Carbon Equivalence and Spot Weld Failure Modes
5 Resistance Spot Welding of Coated Advanced High-Strength Steels
5.1 Overview of Coated Steels
5.2 Welding of Zinc-Coated Steels
5.3 Welding of Coated PHS Steels
6 Resistance Spot Welding of Aluminum
6.1 Overview of Aluminum
6.1.1 Dynamic Resistance Curves
6.1.2 Plastic Range
6.1.3 Thermal and Electrical Conductivity
6.1.4 Coefficient of Thermal Expansion
6.1.5 Oxide Layer
6.2 Spot Welding of Aluminum
6.3 Novel Approaches to Spot Welding Aluminum
6.3.1 GM’s Multi-ringed Domed Electrode
6.3.2 Fronius DeltaSpot Process
6.3.3 Refill Friction Stir Spot Weld (RFSSW) Process
7 Joining Aluminum to Steel—Spot Welding and Other Approaches
7.1 Background
7.2 Spot Welding
7.3 Unique Welding Approaches with Potential for Use on Automotive Assembly Lines
7.3.1 Spot Welding with Rivet-Like Insert
7.3.2 Flexweld
7.4 Mechanical Methods for Joining Aluminum to Steel
7.4.1 Clinching
7.4.2 Self-Pierce Riveting
8 Design and Weld Strength Considerations for Resistance Spot Welding
8.1 Spot Weld Mechanical Property Considerations
8.2 Multiple Sheet Stack-Ups
8.3 One-Sided Welding
8.4 Weld Bonding
9 Resistance Spot Welding Quality, Testing, Monitoring, and Control
9.1 Discontinuities and Defects
9.2 Destructive Testing of Spot Welds
9.2.1 Peel and Chisel Testing
9.2.2 Mechanical Testing
9.3 Nondestructive Evaluation (NDE) and Monitoring Techniques
9.4 Computational Modeling of Resistance Spot Welding
10 Resistance Spot Welding Production Issues
10.1 Electrode Wear
10.1.1 Choice of Electrode Geometry for Long Life
10.1.2 Managing Electrode Wear
10.2 Electrode Cooling
10.3 Electrode Alignment and Part Fit-Up
10.4 Pneumatic Versus Electric Servo Guns
11 Overview of Resistance Spot Welding Codes and Standards
11.1 AWS C1.1
11.2 AWS D8.1
11.3 AWS D8.9
11.4 ISO Standards
11.5 RWMA
