Print ISSN: 1681-6900

Online ISSN: 2412-0758

Keywords : resistance spot welding


Optimization the Resistance Spot Welding Parameters of Austenitic Stainless Steel and Aluminum Alloy Using Design of Experiment Method

Sabah Khammass Hussein; Osamah Sabah Barrak

Engineering and Technology Journal, 2016, Volume 34, Issue 7, Pages 1383-1401

This research aims to study the effect of RSW parameters on the sheerforce of the spot weldedfor two materials {AISI 304L and AA 6061-T6}with (0.5 and 0.7 mm) thickness. Three values for each welding parameters (welding current, electrode force, squeeze time and welding time) are to be used. The effect of those parameters has been analyzed by using design of experiments (DOE) in order to determine and reduce the number of the tested specimens.
The experimental tests have been donethat are;shear, micro hardness tests and microstructure examination. It was found that the maximum shear force in welding of similar material AISI 304L is (F = 4.78 KN for t = 0.7 mm), while in the joint of dissimilar material (AA 6061-T6 with AISI 304L), the maximum shear force is (F = 1.42 KN for t = 0.7 mm). These values have been optimized to reach (F =5.13 KN & F =1.54 KN) respectively by using DOE. The minimum shear force was (F = 0.07 KN in t = 0.5 mm).
It was found that, increasing the welding current and sheet thickness gave an increase in the shear force, but at the same time the reduction in shear force has occurred during the increasing in electrode force, squeeze time and welding time. From micro hardness tests, it was found that the maximum value of hardness was at the center of nugget zone (NZ) and it reduces slightly until reaching constant values away from nugget zone.

Analysis and Optimization of Resistance Spot Welding Parameter of Dissimilar Metals Mild Steel and Aluminum Using Design of Experiment Method

Sabah Khammass Hussein

Engineering and Technology Journal, 2015, Volume 33, Issue 8, Pages 1999-1011

This research aims to study the effect of parameters of the resistance spot welding (RSW) on the shear strength of the spot weld for different metals {AA 6061-T6and AISI 1010}using (0.5 and 0.7 mm) thickness.Three values for each welding parameters (welding current, electrode force, squeeze time and welding time) are to be used. The effect of those parameters have been analyzed by Minitab program by design of experiments (DOE) in order to determine and reduce the number of specimens required to achieve the tests. The design of experiment method which used was Taguchi method
The experimental tests that had been done are shear, Microhardness and microstructure tests.It was found that the maximum shear force in welding of dissimilar metals(AA 6061-T6 with AISI 1010)is (F = 1.14 KN for t = 0.7 mm ).This value has been optimized to reach (F =1.24KN) using DOE. The minimum shear force was(F = 0.25 KN in t = 0.5 mm).
In general, increasing the welding current and sample thickness gave an increase in the shear force, but at the same time the reduction in shear force have occurred during the increasing in electrode force, squeeze time and welding time.From Microhardness tests, the maximum value of hardness is found at the center of nugget zone (NZ) and it reduces slightly until reaching constant values away from NZ.

Improvement of the Strength of Spot Welding Joint for Aluminum Plates Using Powders as Additive

Moneer H. Al-Saadi; Sabah Khammass Hussein

Engineering and Technology Journal, 2013, Volume 31, Issue 13, Pages 2448-2461

This research is interest in increasing the strength of spot welding joint for thin
commercial Aluminum by adding casting component to the welding zone in the form of
powder. Those components are copper, manganese and magnesium which are added in a
different percentages it appear that the strength of the spot welding has been improved
by (14.5%) when adding(0.4 grams of magnesium),(0.1 grams of manganese ) and (0.4
gram of copper).
The powder is added in the welding zone boundary after made a single hole with a
depth of (0.375mm) and a diameter of (1mm) in the center of spot welding point.
To increase the welding strength, five holes have been made with the same above
dimensions through the welding zone boundary. The percentages of additive used after
reparation the reduction of Aluminum powder.
The value of shearing strength increase with a percentage of (27.3%) as comparing
with those without additive.
Also, heat treatment has been done, which gave a redaction in the strength of spot
welding. It has been observed that the increase in the temperature of heat treatment
result in decreasing in the spot strength. Welding and cooling environment have an
effect on the strength of welded specimen. Hence, air welding environment gives a good
welding strength.