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Development of Plasma Arc Spot Welding Process and Finite Element Method Analysis Model for Predicting Fracture Strength: Part 1—Development of Plasma Arc Spot Welding Process

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Abstract

Resistance spot welding is widely used in automobiles and ships, and especially, it accounts for 70% of the body welding process. However, resistance spot welding is limited when welding the closed structure of a vehicle body. As welding is performed by placing a spot gun in a closed structure, a passage is required for the insertion of the spot gun. This passage is called a “passing hole”, and the structural design of the passing hole and the cover that is installed to block the passing hole is complicated, resulting in durability problems as the weight of the vehicle body increases. This study aims to develop a plasma arc spot welding (PASW) process that can replace resistance spot welding. “Part 1 - Development of Plasma Arc Spot Welding Process” determines whether this process can replace the resistance spot welding process through experiments by adjusting the existing process variables of the plasma arc welding process as well as additional process variables. The experimental results of applying the PASW process are then applied to the development of a finite element analysis model for predicting the fracture strength of the PASW process in Part 2.

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Acknowledgement

This work was supported by the National Research Foundation of Korea (NRF) grant funded by the Korea government (MSIT) (No.2021R1A4A1033141) and (No.2021R1F1A106-4238).

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Authors and Affiliations

  1. School of Mechanical Engineering, Chungbuk National University, Cheongju, 28644, Korea

    Geonho Lee, Hansol Kim, Jongho Jeon, Sangjun Han, Sang-Woo Han & Jungho Cho

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  1. Geonho Lee
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  2. Hansol Kim
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  3. Jongho Jeon
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  4. Sangjun Han
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  5. Sang-Woo Han
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  6. Jungho Cho
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Contributions

All authors read and approved the final manuscript. All authors contributed to this paper. Experiments were performed by Geonho Lee, Hansol Kim, Jongho Jeon, and Sangjun Han. Data analysis and result considerations were performed by Geonho Lee, Sang-Woo Han, and Jungho Cho. The first draft of the manuscript was written by Geonho Lee, and all authors commented on previous versions of the manuscript. All authors read and approved the final manuscript.

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Correspondence to Jungho Cho.

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Lee, G., Kim, H., Jeon, J. et al. Development of Plasma Arc Spot Welding Process and Finite Element Method Analysis Model for Predicting Fracture Strength: Part 1—Development of Plasma Arc Spot Welding Process. Int. J. Precis. Eng. Manuf. 24, 1–11 (2023). https://doi.org/10.1007/s12541-022-00707-1

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  • DOI: https://doi.org/10.1007/s12541-022-00707-1

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