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 In this method single pulsed welding current has been replaced by multi-pulsed scheme to analyze the alternations which take place in the electrical and thermal features such as voltage and consequently temperature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.
This is a preview of subscription content, access via your institution.
Buy single article
Instant access to the full article PDF.
Tax calculation will be finalised during checkout.
Atashparva M, Hamedi M (2018) Investigating mechanical properties of small scale resistance spot welding of a nickel based Superalloy through statistical DOE. Exp Tech 42(1):27–43. https://doi.org/10.1007/s40799-017-0221-2
Chabok A, van der Aa E, Basu I, De Hosson J, Pei Y (2018) Effect of pulse scheme on the microstructural evolution, residual stress state and mechanical performance of resistance spot welded DP1000-GI steel. Sci Technol Weld Join 23(8):649–658. https://doi.org/10.1080/13621718.2018.1452875
Chang H, Cho H (1990) A study on the shunt effect in resistance spot welding. Weld J 69(8):308–316
Deng L, Li Y, Cai W, Haselhuhn A, Carlson B (2020a) Simulating thermoelectric effect and its impact on weld nugget asymmetric growth in aluminum resistance spot welding. J Manuf Sci Eng 142:1–24. https://doi.org/10.1115/1.4047243
Deng L, Li Y, Cai W, Haselhuhn AS, Carlson BE (2020b) Simulating thermoelectric effect and its impact on asymmetric weld nugget growth in aluminum resistance spot welding. J Manuf Sci Eng 142(9)
Haghshenas N, Moshayedi H (2020) Monitoring of resistance spot welding process. Exp Tech 44(1):99–112. https://doi.org/10.1007/s40799-019-00341-z
Hard A (1948) Preliminary test of spot weld shunting in 24ST Alclad. Weld J 27(6):491–495
Jafari Vardanjani M, Araee A, Senkara J, Jakubowski J, Godek J (2016a) Metallurgical effects of shunting current on resistance spot-welded joints of AA2219 sheets. J Mater Eng Perform 25(8):3506–3517. https://doi.org/10.1007/s11665-016-2168-3
Jafari Vardanjani M, Araee A, Senkara J, Jakubowski J, Godek J (2016b) Theoretical analysis of shunting effect in resistance spot welding (RSW) of AA2219. J Chin Inst Eng 39(8):907–918. https://doi.org/10.1080/02533839.2016.1215940
Khan L, Kunts M, Zhou Y, Chan K, Scotchmer N (2007) Monitoring the effect of RSW pulsing on AHSS using FEA (SORPAS) software. doi:https://doi.org/10.4271/2007-01-1370
Lee Y, Jeong H, Park K, Kim Y, Cho J (2017) Development of numerical analysis model for resistance spot welding of automotive steel. J Mech Sci Technol 31(7):3455–3464
Li Y, Wang B, Shen Q, Lou M, Zhang H (2013) Shunting effect in resistance spot welding steels—part 2: theoretical analysis. Welding Journal 92(8):231s–238s
Liu X, Wei Y (2020) Direct finite element analysis of the stress evolution and interaction in resistance spot welding with multiple processes and multiple spots based on reverse engineering technology. J Mater Eng Perform 29(8):5490–5502
Moharrami R, Hemmati B (2017) Numerical stress analysis in resistance spot-welded nugget due to post-weld shear loading. J Manuf Process 27:284–290
Nied H (1984) The finite element modeling of the resistance spot welding process. Weld J 63(4):123
Podržaj P, Simončič S (2013) Temperature measurement during resistance spot welding using a digital camera. Paper presented at the 2013 IEEE international conference on mechatronics and automation
Senkara J, Zhang H (2000) Cracking in spot WELDING aluminum alloy AA5754. Welding Journal-New York 79(7):194-s
Shen J, Zhang Y, Lai X, Wang P (2011) Modeling of resistance spot welding of multiple stacks of steel sheets. Mater Des 32(2):550–560
Sigler DR, Carlson B, Janiak P (2013) Improving aluminum resistance spot welding in automotive structures. Weld J 92:64–72
Sun X, Dong P (2000) Analysis of aluminum resistance spot WELDING processes using coupled finite element procedures. Welding Journal-New York 79(8):215-S
Sun X, Stephens E, Khaleel M, Shao H, Kimchi M (2004) Resistance Spot Welding of Aluminum Alloy to Steel with Transition Material - From Process to Performance - Part I: Experimental Study 83
Vardanjani MJ, Araee A, Senkara J, Jakubowski J, Godek J (2016a) Experimental and numerical analysis of shunting effect in resistance spot welding of Al2219 sheets. Bull Polish Acad Sci Technical Sci 64:2
Vardanjani MJ, Araee A, Senkara J, Sohrabian M, Zarandooz R (2016b) Influence of shunting current on the metallurgical and mechanical behaviour of resistance spot-welded joints in AA2219 joints. 62(11), 11. doi:https://doi.org/10.5545/sv-jme.2016.3682
Vardanjani MJ, Ghayour M, Homami RM (2016c) Analysis of the vibrational stress relief for reducing the residual stresses caused by machining. Exp Tech 40(2):705–713. https://doi.org/10.1007/s40799-016-0071-3
Vodă M, Codrean C, Chicot D, Şerban V-A, Uţu D, Linul E, Buzdugan D (2019) Characterization of brazed joints by electrical resistance spot brazing with Ni-based amorphous self-flux alloys. J Manuf Process 37:617–627. https://doi.org/10.1016/j.jmapro.2018.10.029
Vogler M, Sheppard S (1993) Electrical contact resistance under high loads and elevated temperatures Welding Journal, 72
Wang B, Hua L, Wang X, Li J (2016) Effects of multi-pulse tempering on resistance spot welding of DP590 steel. Int J Adv Manuf Technol 86(9):2927–2935. https://doi.org/10.1007/s00170-016-8361-6
Wang B, Lou M, Shen Q, Li Y, Zhang H (2013) Shunting effect in resistance spot welding steels—part 1: experimental study. Welding J 92(6):182s–189s
Weiss JSAV (1966) Materials data handbook- aluminum alloy 2219: Western Applied Research & Development
Zhang H, Senkara J (2011) Resistance welding: fundamentals and applications, Second Edition: CRC Press
Zhang H, Senkara J, Wu X (2002) Suppressing cracking in resistance welding AA5754 by mechanical means. J Manuf Sci Eng 124(1):79–85
Zhang W (2003) Design and implementation of software for resistance welding process simulations. SAE Trans, 556–564
Zhao Y, Zhang Y, Lai X (2018) Analysis of fracture modes of resistance spot welded hot-stamped boron steel. Metals 8(10):764
Conflict of Interest
On behalf of all authors, the corresponding author states that there is no conflict of interest.
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
About this article
Cite this article
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
- Resistance spot welding
- Multi-pulsed current
- Finite element analysis