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Electrode-Sheet Interactions During Resistance Spot Welding of Aluminum
Published September 30, 1997 by Automotive Technology Group, Inc. in United States
Spot-welded body structures made of aluminum alloys are now being widely used in the automotive industry. Higher current and squeezing force are required for the spot welding of aluminum alloys compared with steel because of their higher thermal and electrical conductivity. The resulted higher electrode face temperature and pressure lead to accelerated electrode wear.
In this study, an advanced finite element procedure is used to analyze the electrode-sheet interactions during the spot-welding processes. This analysis procedure takes into account the instantaneous changes in nugget development and contact area, as well as current density profile. Two specific electrode tip conditions are investigated with an emphasis on implications of electrode wear mechanism, weld indentation, final sheet separation and weld residual stresses. The purpose of the study is to provide some fundamental understandings on the electrode-sheet interactions, and how they affect the process dynamics during the aluminum resistance spot welding.