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Modifying electrode force during welding cycle is a valid method to obtain acceptable nugget with shorter welding time or less energy.
Some of these particles remain undissolved at the peak temperature of a welding thermocycle and may result in sympathetic nucleation of new particles on them.
The effects of welding current and current duration to nugget nucleation can be characterized by the characteristic parameters of acoustic emission signals.
The nucleation mechanism may also arise in other contexts.
Thus, in this case, nucleation is controlled by the combustion process.
revealed that the nucleation mechanism was heterogeneous nucleation, rather than grain detachment and dendrite fragmentation.
Open accessJournal ArticleDOI
Amit Kumar, M.K. Khurana, Pradeep K Yadav 
01 Sep 2016
13 Citations
The results revealed that the welding speed is most significant process parameter.
In the case of heterogeneous nucleation, we can also obtain at least some information on what is responsible for nucleation.
This enables high deposition rate welding for significant increase in productivity.
It proved that the jet formation is an important condition for the solid-state welding.
However, to what extent these can be related to nucleation behavior on larger (industrial) scales is not known.
The results showed that the physical phases of nugget nucleation can be characterized by the acoustic emission signals detected during the resistance spot welding process.
The results indicated that critical nucleation radiuses in two models are the same, which were slightly affected by welding current.
It is, thus, accepted as a clean welding process that can produce acceptable quality joints.

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