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Experimental and numerical simulation on forming and thermal distribution of a new composite annular electrode joint

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Abstract

When welding high-strength steel and ultra-thin plates, traditional resistance spot welding has technical problems such as a narrow process window and difficulty in ensuring both welding strength and forming quality, making it one of the bottlenecks in the manufacture of high-end structural parts in the fields of vehicles, aviation, and aerospace. The core reason is that the traditional spot welding thermal cycle mode is single, the energy is highly concentrated, and the controllability is poor. Therefore, there is an inconsistency between its energy distribution and nugget quality. In view of the above difficulties, a new idea of resistance spot welding of special-shaped electrodes based on energy distribution design is proposed. By inlaying insulating ceramics and other materials on the electrode end face, a “composite annular electrode” is prepared to realize the regulation of energy distribution in the welding process. In this paper, experimental and numerical simulation are carried out to reveal the detailed influence of the diameter of the ceramic core on the joint forming and thermal distribution. The results show that the welding effect of composite annular electrodes is better than that of traditional electrodes under different thickness plates. The maximum strength of the joint can reach 2600 N. The maximum temperature during welding shall not exceed 1930 °C. And the optimal ceramic core diameter is optimized for ultra-thin plates and high-strength steel plates commonly used in automobiles.

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Funding

This research is financially supported by the Anhui University Natural Science Fund project(KJ2021A0417), the High-level Scientific Research Startup Fund for the Introduction of Talent of Anhui University of Science and Technology, the National Natural Science Foundation of China (51775160), and the China Postdoctoral Science Foundation (2020M680947).

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Authors and Affiliations

  1. School of Mechanical Engineering, Anhui University of Science and Technology, Huainan, 232000, China

    Zhao Dewang, Zhang Chao & Zhao Kunmin

  2. Key Laboratory of Liaoning Advanced Welding and Joining Technology, Dalian, 116024, China

    Zhao Dewang & Ren Daxin

  3. School of Automotive Engineering, Dalian University of Technology, Dalian, 116024, China

    Ren Daxin

  4. Hezhong New Energy Automotive Co., Ltd., Tongxiang, 314500, China

    Zhao Kunmin

Authors
  1. Zhao Dewang
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  2. Zhang Chao
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  3. Ren Daxin
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  4. Zhao Kunmin
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Contributions

The author contributions are as follows: Dewang Zhao and Kunmin Zhao were in charge of the whole trial; Dewang Zhao and Chao Zhang wrote the manuscript; Daxin Ren assisted with experimentation; Dewang Zhao and Daxin Ren assisted with FEM. All authors read and approved the final manuscript.

Corresponding author

Correspondence to Zhao Kunmin.

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Dewang, Z., Chao, Z., Daxin, R. et al. Experimental and numerical simulation on forming and thermal distribution of a new composite annular electrode joint. Int J Adv Manuf Technol 125, 213–229 (2023). https://doi.org/10.1007/s00170-022-10690-6

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  • DOI: https://doi.org/10.1007/s00170-022-10690-6

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