Skip to main content
SpringerLink
Log in

Weld nugget formation in resistance spot welding of new lightweight sandwich material

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

Weldability of a new lightweight sandwich material, LITECOR®, by resistance spot welding is analyzed by experiments and numerical simulations. The spot welding process is accommodated by a first pulse squeezing out the non-conductive polymer core of the sandwich material locally to allow metal–metal contact. This is facilitated by the use of a shunt tool and is followed by a second pulse for the actual spot welding and nugget formation. A weldability lobe in the time-current space of the second pulse reveals a process window of acceptable size for automotive assembly lines. Weld growth curves are presented together with results of numerical simulations made in the finite element computer program SORPAS® 3D, which is based on an electro-thermo-mechanical formulation. The numerical models are presented together with the specific modeling conditions leading to numerical simulations in good agreement with experimental results in the range of welding parameters leading to acceptable weld nugget sizes. The validated accuracy of the commercially available software proves the tool useful for assisting the choice of welding parameters.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. Belingardi G (2014) Lightweight design of vehicle body a contribution toward greener environment. Acta Technica Corviniensis - Bulletin of Engineering, Tome VII, Hunedoara, Romania, pp 165–169

    Google Scholar 

  2. Cordes R, Welsch F (2002) The new VW Polo—an example of modern lightweight body construction (in German). Dev Chassis Eng 1674:3–17

    Google Scholar 

  3. Hillebrecht M, Broek CT, Singh H (2012) Lightweight design for the future steel vehicle. Auto Tech Review 1(11):24–30

    Article  Google Scholar 

  4. Singh S (2004) Can simulation of the welding process help advance the state of the art in resistance welding?, The 3rd International Seminar on Advances in Resistance Welding, Berlin, Germany, 5–11

  5. Satonaka S, Iwamoto C, Qui R, Fujioka T (2006) Trends and new applications of spot welding for aluminium alloy sheets. Weld Int 20(11):858–864

    Article  Google Scholar 

  6. Qui R, Iwamoto C, Satonaka S (2009) Interfacial microstructure and strength of steel/aluminum alloy joints welded by resistance spot welding with cover plate. J Mater Process Technol 209:4186–4193

    Article  Google Scholar 

  7. Rudolf H, Yang Y, Broda T, Kotschote C (2013) Neuartige Widerstandspunktschweissenverfahren für den automobilen Aluminium-Stahl-Mischbau (in German), 22. DVS Sondertagung Widerstandsschweissen, Duisburg, Germany, pp 151–157

    Google Scholar 

  8. Meschut G, Hahn O, Janzen V, Olfermann T (2014) Innovative joining technologies for multi-material structures. Weld World 58:65–75

    Article  Google Scholar 

  9. Kotschote C, Neudel C, Bergmann JP, Rudolf H (2013) Widerstandspunktschweissen von Aluminium-Stahl-Blechverbindungen mittels innenliegenden Stanzelementes (in German), 22. DVS Sondertagung Widerstandsschweissen, Duisburg, Germany, pp 1–6

    Google Scholar 

  10. Hoffmann O (2012) Environment oriented light weight design in steel. Ökologischer Leichtbau in Stahl, Hannovermesse Werkstoff-Forum, Hannover, Germany

    Google Scholar 

  11. Hoffmann O (2012) Steel lightweight materials and design for environmentally friendly mobility, Industrial Technologies 2012 integrating nano, materials and production. Aarhus, Denmark

    Google Scholar 

  12. Zhang W, Chergui A, Nielsen CV (2012) Process simulation of resistance weld bonding and automotive light-weight materials, The 7th International Seminar on Advances in Resistance Welding. Busan, Korea, pp 67–75

    Google Scholar 

  13. Wu P (2004) Testing and modeling of machine properties in resistance welding, PhD Thesis, Technical University of Denmark

  14. Nielsen CV, Zhang W, Alves LM, Bay N, Martins PAF (2012) Modeling of thermo-electro-mechanical manufacturing processes with applications in metal forming and resistance welding. Springer, London

    Google Scholar 

  15. Nielsen CV, Zhang W, Martins PAF, Bay N (2015) 3D numerical simulation of projection welding of square nuts to sheets. J Mater Process Technol 215:171–180

    Article  Google Scholar 

  16. Zhang W (2003) Design and implementation of software for resistance welding process simulations. Trans: J Mater Manuf 112(5):556–564

    Google Scholar 

  17. Bowden FP, Tabor D (1950) The fabrication and lubrication of solids, Oxford University Press

Download references

Author information

Authors and Affiliations

  1. Department of Mechanical Engineering, Technical University of Denmark, Produktionstorvet 425, 2800, Kgs. Lyngby, Denmark

    J. Sagüés Tanco, C. V. Nielsen & N. Bay

  2. Dortmund FuE-A Pressfügen/Kleben, ThyssenKrupp, Dortmund, Germany

    A. Chergui

  3. SWANTEC Software and Engineering ApS, Kgs. Lyngby, Denmark

    W. Zhang

Authors
  1. J. Sagüés Tanco
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. C. V. Nielsen
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. A. Chergui
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. W. Zhang
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. N. Bay
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to C. V. Nielsen.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Tanco, J.S., Nielsen, C.V., Chergui, A. et al. Weld nugget formation in resistance spot welding of new lightweight sandwich material. Int J Adv Manuf Technol 80, 1137–1147 (2015). https://doi.org/10.1007/s00170-015-7108-0

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-015-7108-0

Keywords

Search

Navigation