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On the nondestructive testing and monitoring of cracks in resistance spot welds: recent gained experience

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Abstract

The current paper addresses the challenge of steel and modern automotive industries in the detection of liquid metal embrittlement (LME) crack when occurring during resistance spot welding of advanced high strength steel. While progress has been made to understand and prevent LME crack occurrence, its detection and characterization are still the main concern. Unfortunately, these aspects have received scarce attention in the literature. In this study, various non-destructive testing solutions (NDT) for crack detection and characterization (in particular depth estimation) were developed using novel algorithms and hardware. Despite the complex features of LME crack, its detection and characterization are promising: acoustic emission testing (AT) was found to be efficient for crack detection using a novel criterion based on Shannon entropy. Unprecedented AT tests have even been carried out in serial automotive production environments to assess deployment feasibility. The machine vision algorithm was implemented for magnetic inspection to assess crack detection automation. For crack depth estimation, three solutions are discussed using pulsed thermography, Eddy current array, and industrial large scale tomography (RoboTom). This paper focuses on gained experience and recommendations that would help the research community to increase the technology readiness of LME crack detection and characterization.

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Acknowledgements

This work was supported by the WorldAutoSteel consortium and was performed as part of the transnational liquid metal embrittlement in the AHSS program. The authors are grateful for their partners: University of Paderborn, IPK Fraunhofer, ArcelorMittal, Baomarc, RayScan Technologies, and Eddyfi Technologies. Several experimental works were carried out in their facilities.

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Authors and Affiliations

  1. Institut de Soudure, Equipe Monitoring et Intelligence Artificielle, 4 boulevard Henri Becquerel, 57970, Yutz, France

    Fethi Dahmene, Slah Yaacoubi, Mahjoub El Mountassir, Abd Ennour Bouzenad, Pierre Rabaey, Mohamed Masmoudi & Pascal Nennig

  2. ArcelorMittal, Maizières Research, Voie Romaine, 57280, Maizières-lès-Metz, France

    Thomas Dupuy, Yacine Benlatreche & Abdoulaye Taram

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  1. Fethi Dahmene
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  2. Slah Yaacoubi
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Correspondence to Fethi Dahmene or Slah Yaacoubi.

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Dahmene, F., Yaacoubi, S., Mountassir, M.E. et al. On the nondestructive testing and monitoring of cracks in resistance spot welds: recent gained experience. Weld World 66, 629–641 (2022). https://doi.org/10.1007/s40194-022-01249-w

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