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The Role of Lug Preheating, Melt Pool Temperature, and Lug Entrance Delay on the Cast-on-Strap Joining Process

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Abstract

This work deals with effective parameters in the cast-on-strap (COS) process during which grid lugs of a lead-acid battery are joined together by a strap. The effects of lug preheating, melt pool temperature, and lug entrance delay on the quality of joints and casting defects were investigated. Lug preheating was found to propitiously reduce joint internal voids because of flux elimination. Its adverse effect on lowering lug wettability, however, made it unfavorable under the experimental conditions. The melt pool temperature also showed a two-sided effect depending on the process conditions. Raising the temperature increases the strap melt fluidity, which improves the joint contact area; however, it has a negative effect on lug wettability by flux evaporation. Besides, higher temperatures cause more lug back-melting and, hence, lower relative contact lengths. Therefore, an intermediate temperature of 683 K (410 °C) was found to make the most proper condition. Moreover, the case at which the lugs enter the mold coincident with its filling by the melt rendered the best joint quality. In this condition, the melt flows through the interlug spaces, which helps the voids to escape, resulting in the better joint interface. As the conclusion, the lug entrance time has the most effective role on joint quality, considering that lug preheating does not show any improving effect.

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Acknowledgments

The authors express their gratitude to Supplying Automotive Parts Co. (Sapco) and Nirougostaran Khorasan Co. for financial support. Mr. M. Mohammadzadeh is also gratefully acknowledged for his consults during the project.

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Authors and Affiliations

  1. Materials and Metallurgical Engineering Department, Faculty of Engineering, Ferdowsi University of Mashhad, Mashhad, 91775-1111, Iran

    Sohrab Pahlavan, Saman Nikpour, Mostafa Mirjalili & Iman Taji

  2. Research and Development Center, Nirougostaran Khorasan Co., Mashhad, 91775-1486, Iran

    Ali Alagheband & Mohammadyousef Azimi

Authors
  1. Sohrab Pahlavan
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  2. Saman Nikpour
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  3. Mostafa Mirjalili
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  4. Ali Alagheband
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  5. Mohammadyousef Azimi
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  6. Iman Taji
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Corresponding author

Correspondence to Mostafa Mirjalili.

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Manuscript submitted November 26, 2016.

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Pahlavan, S., Nikpour, S., Mirjalili, M. et al. The Role of Lug Preheating, Melt Pool Temperature, and Lug Entrance Delay on the Cast-on-Strap Joining Process. Metall Mater Trans A 48, 3318–3327 (2017). https://doi.org/10.1007/s11661-017-4094-x

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  • DOI: https://doi.org/10.1007/s11661-017-4094-x

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