Skip to main content
SpringerLink
Log in

Numerical and experimental study on nugget formation process in resistance spot welding of aluminum alloy

  • Published:
Transactions of Tianjin University Aims and scope Submit manuscript

Abstract

The weld nugget formation in the resistance spot welding (RSW) of aluminum alloy was investigated in the present study. The nugget formation process was directly observed by using a digital high-speed camera. Numerical simulation was also employed to investigate the nugget formation process. The results showed that for the RSW of two aluminum alloy sheets, a nugget was first formed in the workpiece/workpiece (W/W) interface and grew along the radial direction and axial direction of the sheets, and then it became a large elliptical nugget. For the RSW of three aluminum alloy sheets, two small nuggets were firstly formed in two W/W interfaces and grew along the axial direction and radial direction; finally they fused into one nugget. Besides, there existed a critical welding time, after which the nugget size remained nearly unchanged. This indicates that a long welding time is unnecessary for the RSW of aluminum alloy. In addition, the calculated nugget radius was compared with the experimental results, which showed that the simulation results agreed well with the experimental results.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. Gould J E. Examination of nugget development during spot welding using both experimental and analytical techniques[J]. Welding Journal, 1987, 66(1): 1s–10s.

    Google Scholar 

  2. Eisazadeh H, Hamedi M, Halvaee A. New parametric study of nugget size in resistance spot welding process using finite element method[J]. Materials and Design, 2010, 31(1): 149–157.

    Article  Google Scholar 

  3. Li Y B, Lin Z Q, Shen Q. Numerical analysis of transport phenomena in resistance spot welding process[J]. ASME Journal of Manufacturing Science and Engineering, 2011, 133: 031019.

    Article  Google Scholar 

  4. Moshayedi Hessamoddin, Sattari-Far Iradj. Numerical and experimental study of nugget size growth in resistance spot welding of austenitic stainless steels[J]. Journal of Materials Processing Technology, 2012, 212(2): 347–354.

    Article  Google Scholar 

  5. De A. Finite element modeling of resistance spot welding of aluminum with spherical tip electrodes[J]. Science and Technology of Welding and Joining, 2002, 7(2): 119–124.

    Article  Google Scholar 

  6. Hamedi M, Pashazadeh H. Numerical study of nugget formation in resistance spot welding[J]. International Journal of Mechanics, 2008, 2(1): 11–15.

    Google Scholar 

  7. Khan J A, Xu L, Chao Y J. Prediction of nugget development during resistance spot welding using coupled thermal-electrical-mechanical model[J]. Science and Technology of Welding and Joining, 1999, 4(4): 201–207.

    Article  Google Scholar 

  8. Upthegrove W R, Key J F. A high speed photographic analysis of spot welding galvanized steel[J]. Welding Journal, 1972, 51(5): 233s–244s.

    Google Scholar 

  9. Kim E W, Eagar T W. Measurement of transient temperature response during resistance spot welding[J]. Welding Journal, 1989, 68(8): 303s–312s.

    Google Scholar 

  10. Cho Y, Rhee S. Experimental study of nugget formation in resistance spot welding[J]. Welding Journal, 2003, 82(8): 195s–201s.

    Google Scholar 

Download references

Author information

Authors and Affiliations

  1. School of Materials Science and Engineering, Tianjin University, Tianjin, 300072, China

    Zhen Luo  (罗 震), Fuyu Yan  (颜福裕), Yang Li  (李 洋), Yang Bai  (白 杨), Qi Yao  (姚 杞) & Hui Tan  (谈 辉)

Authors
  1. Zhen Luo  (罗 震)
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Fuyu Yan  (颜福裕)
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Yang Li  (李 洋)
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Yang Bai  (白 杨)
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Qi Yao  (姚 杞)
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Hui Tan  (谈 辉)
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Zhen Luo  (罗 震).

Additional information

Supported by the National Natural Science Foundation of China (No. 51275342 and No. 51275338).

Luo Zhen, born in 1967, male, Dr, Prof.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Luo, Z., Yan, F., Li, Y. et al. Numerical and experimental study on nugget formation process in resistance spot welding of aluminum alloy. Trans. Tianjin Univ. 21, 135–139 (2015). https://doi.org/10.1007/s12209-015-2356-5

Download citation

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s12209-015-2356-5

Keywords

Search

Navigation