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Effect of Multi-Pulsed Current Mechanism on Shunting Current in Resistance Spot Welding (RSW) of AA-2219 Sheets

Abstract

Shunting phenomenon takes place when the electrical current passes through the prior weld spots. So far there have been few areas of the shunting impact studied while this is a prevalent effect in intermittent resistance spot welding (RSW). The magnitude of this current depends predominantly on distance, number, and the size of the previous spot welds. In particular this impact creates some dimensional and metallurgical alteration in the weld nugget (Fusion zone) and heat-affected zone (HAZ) as well. In this paper an electrical current modification has been evaluated for reducing the shunting effect in which the welding current profile has been manipulated. In this method single pulsed welding current has been replaced by multi-pulsed scheme to analyze the alternations which take place in the electrical and thermal features such as voltage and consequently temperature distribution respectively caused by the shunting effect. These issues are then analyzed to inspect mechanical and metallurgical attributes of the final spot weld which has been affected by shunting current. Numerical and experimental results are then compared with spot welds produced by ordinary single pulse welding current. The results demonstrate logical optimization of joint quality after welding current modification according to the proposed method mechanically and metallurgically.

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Correspondence to M. Jafari Vardanjani.

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Jafari Vardanjani, M., Senkara, J. Effect of Multi-Pulsed Current Mechanism on Shunting Current in Resistance Spot Welding (RSW) of AA-2219 Sheets. Exp Tech (2021). https://doi.org/10.1007/s40799-021-00504-x

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Keywords

  • Resistance spot welding
  • Shunting
  • Multi-pulsed current
  • Finite element analysis
  • Experiment