Electric resistance welding

About: Electric resistance welding is a research topic. Over the lifetime, 16761 publications have been published within this topic receiving 154851 citations.

Characterization of Joint Quality in Ultrasonic Welding of Battery Tabs

Abstract: Manufacturing of lithium-ion battery packs for electric or hybrid electric vehicles requires a significant amount of joining such as welding to meet desired power and capacity needs. However, conventional fusion welding processes such as resistance spot welding and laser welding face difficulties in joining multiple sheets of highly conductive, dissimilar materials with large weld areas. Ultrasonic metal welding overcomes these difficulties by using its inherent advantages derived from its solid-state process characteristics. Although ultrasonic metal welding is well-qualified for battery manufacturing, there is a lack of scientific quality guidelines for implementing ultrasonic welding in volume production. In order to establish such quality guidelines, this paper first identifies a number of critical weld attributes that determine the quality of welds by experimentally characterizing the weld formation over time. Samples of different weld quality were cross-sectioned and characterized with optical microscopy, scanning electronic microscopy (SEM), and hardness measurements in order to identify the relationship between physical weld attributes and weld performance. A novel microstructural classification method for the weld region of an ultrasonic metal weld is introduced to complete the weld quality characterization. The methodology provided in this paper links process parameters to weld performance through physical weld attributes.Copyright © 2012 by ASME and General Motors

Hot cracking in Al–Mg–Si alloy laser welding – operating parameters and their effects

Abstract: Hot cracking is a phenomenon that frequently occurs in the laser welding of some “special” alloys, such as the aluminium–magnesium–silicon type. Each occurrence of this phenomenon needs to be studied in itself, taking into account not only the individual, but also the interactive, influences of the various parameters. The advantage of using laser beams in welding processes lies in the speeds that can be reached. The disadvantage, however, is that, owing to the high cooling rates characteristic of the interaction between the laser beam and the material, the welding speed itself becomes a cause of hot cracking. The aim of this paper is to see how this disadvantage may be eliminated. We consider what the most important parameters may be, relating to tensile strength and the quantity of cracks produced, that might influence the presence or absence of hot cracking. The most influential factors in avoiding hot cracking are the welding speed and wire parameters. Also important is welding stability, as instability generates cracks. We can then determine a technological window, useful for industrial applications, which takes into account the values of these influential factors and stability.

A dynamic model of drops detaching from a gas metal arc welding electrode

Abstract: A dynamic model of drop detachment in gas metal arc welding is presented for low and moderate welding currents in an argon-rich plasma. Simulations performed with this model are compared with extensive experimental measurements of constant-current welding images and with limited experimental measurements of pulsed-current welding images. The comparisons indicate that the experimental axial magnetic forces are much less potent than the calculated axial magnetic forces when welding-current transients are not present. To explain this finding the hypothesis that internal flows are able to develop under the relatively quiescent conditions that exist during drop development in constant-current welding is advanced.

Weldability of thermoplastic materials for friction stir welding- A state of art review and future applications

Abstract: Polymer composites have certain advantages over metals in terms of mechanical as well as metallurgical properties. These can be joined with similar as well as dissimilar polymer composites (subject to certain conditions like glass transition temperature, rheological properties etc.). In last 20-25 years number of techniques and concepts has been developed to offer the possibility of joining of polymeric materials which have similar or dissimilar characteristics. In present scenario mechanical fastening and adhesive bonding is replaced by applying welding concepts like: laser transmission welding, friction stir welding (FSW), ultrasonic welding, hot fusion resistance welding etc. The FSW is one of the most acceptable welding techniques for production of structural/industrial components. In this present work, requirements of FSW and its process capability has been highlighted for joining of similar/dissimilar polymeric materials for future prospective.