Author : Prof.Sushil T Ambadkar 1
Date of Publication :13th April 2017
Abstract: Resistance spot welding has been widely used as welding process for manufacturing auto-body, aerospace and electronics structures. The motor vehicle makes extensive application of Resistance spot welding with 2000 and 5000 spot welds. The process is used in these applications due to high productivity, flexibility, and suitability. It is the mechanical performance of spot weld which controls performance of vehicle structure in crash. In this review , type of the joints covered are i) Spot welding of triple-thin-sheet aluminium alloy ii)Resistance spot welding of three different dissimilar aluminium alloy stackups that included die cast Aural2T7 to Aural2T7,Aural2T7 to AA5754O, and Aural2T7 to AA6022T4 iii) Resistance spot welding between AISI 430 ferritic stainless steel and drawing quality special killed (DQSK) low-carbon steel iv) Resistance spot welding of AZ31B Mg alloy to Al Alloy 5754 using Zn foil and Zn-coated steel interlayer v) Spot welding of advanced high strength steels The materials considered are Aluminium, Aural2T7, AA5754O and AA6022T4, AISI 430 ferritic stainless steel and drawing quality special killed (DQSK) low-carbon steel, AZ31B Mg alloy and Al Alloy 5754.The failure modes, changes obtained in microstructure, bonding, phases and properties for different materials welded using spot welding are discussed. In spot welding of triple-thin-sheet aluminium alloy, an analytical model, which is suitable for the three-sheet aluminium alloy resistance spot weld, was proposed to ensure the pullout failure mode. The critical weld button size required to ensure the pullout failure mode was obtained. Weld nuggets produced with spot welding of die cast Aural2T7 to Aural2T7,Aural2T7 to AA5754O, and Aural2T7 to AA6022T4 were compared for yield strength, strengthening etc. The microstructure and mechanical performance of dissimilar resistance spot welds between AISI 430 ferritic stainless steel and drawing quality special killed (DQSK) low-carbon steel was discussed with reference to peak load, failure energy, and failure mode during the tensile-shear test. Resistance spot welding of AZ31B Mg alloy to Al Alloy 5754 was studied using Zn foil and Zn-coated steel inter-layers. Mechanical properties and microstructure of the welds were analyzed. In spot welding of advanced high strength steels an optimization strategy for the spot welding process was developed to improve fatigue performance of spot welds
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