Investigating feasibility of interlayers in Resistance Spot Welding of low-carbon steel sheets
Abstract In this study, experiments without interlayers and with interlayers of copper and stainless-steel sheets were performed. Design of Experiments based Full-Factorial Method was employed to generate experimental combinations. A total 81 samples were welded and tested in Universal Testing Machi...
| Main Authors: | , , |
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| Format: | Article |
| Language: | English |
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Springer
2021-07-01
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| Series: | SN Applied Sciences |
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| Online Access: | https://doi.org/10.1007/s42452-021-04730-1 |
| _version_ | 1829134891446435840 |
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| author | Vishesh Dharaiya Avinash Panchal G. D. Acharya |
| author_facet | Vishesh Dharaiya Avinash Panchal G. D. Acharya |
| author_sort | Vishesh Dharaiya |
| collection | DOAJ |
| description | Abstract In this study, experiments without interlayers and with interlayers of copper and stainless-steel sheets were performed. Design of Experiments based Full-Factorial Method was employed to generate experimental combinations. A total 81 samples were welded and tested in Universal Testing Machine to determine their Breaking Load. To investigate feasibility considering vehicle lightweightness, a novel LTW (Load-to-Weight) ratio has been proposed. Calculated LTW ratio for each experiment clearly showed that samples with stainless-steel interlayer outperformed over samples with copper interlayer and samples without interlayer. For feasibility in terms of machine durability, electrode corrosion has been found as the most auspicious parameter among all. Spot welding electrodes attain air oxidation above 700 °C. An FEA solver has been employed to determine time for electrodes to remain above air oxidation temperature during a single welding cycle through numerical simulation. A novel LTT (Load-to- Time) ratio has been proposed to find experimental combinations considering feasibility regarding electrode corrosion. LTT ratio, applied to experimental combinations with SS interlayer helped in selection of suitable process parameter combinations. Selected combinations through LTW and LTT ratio can be further proposed to industries. Study advocates method to calculate LTW ratio initially, following calculation of LTT ratio and eventually selecting process parameters contemplating feasibility in lightweightness and electrode corrosion. Article Highlights Study helps to decide feasibility of interlayer in RSW in terms of weight and electrode corrosion. Load-to-Weight (LTW) ratio is proposed to decide feasibility of interlayer in terms of weight. Load-to-Time (LTT) ratio is proposed to determine feasibility of interlayer against electrode corrosion. |
| first_indexed | 2024-12-14T18:13:19Z |
| format | Article |
| id | doaj.art-7fd47c3f1adc464d94fc297407bd316f |
| institution | Directory Open Access Journal |
| issn | 2523-3963 2523-3971 |
| language | English |
| last_indexed | 2024-12-14T18:13:19Z |
| publishDate | 2021-07-01 |
| publisher | Springer |
| record_format | Article |
| series | SN Applied Sciences |
| spelling | doaj.art-7fd47c3f1adc464d94fc297407bd316f2022-12-21T22:52:14ZengSpringerSN Applied Sciences2523-39632523-39712021-07-013811510.1007/s42452-021-04730-1Investigating feasibility of interlayers in Resistance Spot Welding of low-carbon steel sheetsVishesh Dharaiya0Avinash Panchal1G. D. Acharya2Department of Mechanical Engineering, Marwadi UniversityDepartment of Mechanical Engineering, Atmiya Institute of Technology and ScienceAtmiya Institute of Technology and ScienceAbstract In this study, experiments without interlayers and with interlayers of copper and stainless-steel sheets were performed. Design of Experiments based Full-Factorial Method was employed to generate experimental combinations. A total 81 samples were welded and tested in Universal Testing Machine to determine their Breaking Load. To investigate feasibility considering vehicle lightweightness, a novel LTW (Load-to-Weight) ratio has been proposed. Calculated LTW ratio for each experiment clearly showed that samples with stainless-steel interlayer outperformed over samples with copper interlayer and samples without interlayer. For feasibility in terms of machine durability, electrode corrosion has been found as the most auspicious parameter among all. Spot welding electrodes attain air oxidation above 700 °C. An FEA solver has been employed to determine time for electrodes to remain above air oxidation temperature during a single welding cycle through numerical simulation. A novel LTT (Load-to- Time) ratio has been proposed to find experimental combinations considering feasibility regarding electrode corrosion. LTT ratio, applied to experimental combinations with SS interlayer helped in selection of suitable process parameter combinations. Selected combinations through LTW and LTT ratio can be further proposed to industries. Study advocates method to calculate LTW ratio initially, following calculation of LTT ratio and eventually selecting process parameters contemplating feasibility in lightweightness and electrode corrosion. Article Highlights Study helps to decide feasibility of interlayer in RSW in terms of weight and electrode corrosion. Load-to-Weight (LTW) ratio is proposed to decide feasibility of interlayer in terms of weight. Load-to-Time (LTT) ratio is proposed to determine feasibility of interlayer against electrode corrosion.https://doi.org/10.1007/s42452-021-04730-1Resistance Spot WeldingInterlayerFeasibilityTensile-Shear strengthElectrode Corrosion |
| spellingShingle | Vishesh Dharaiya Avinash Panchal G. D. Acharya Investigating feasibility of interlayers in Resistance Spot Welding of low-carbon steel sheets SN Applied Sciences Resistance Spot Welding Interlayer Feasibility Tensile-Shear strength Electrode Corrosion |
| title | Investigating feasibility of interlayers in Resistance Spot Welding of low-carbon steel sheets |
| title_full | Investigating feasibility of interlayers in Resistance Spot Welding of low-carbon steel sheets |
| title_fullStr | Investigating feasibility of interlayers in Resistance Spot Welding of low-carbon steel sheets |
| title_full_unstemmed | Investigating feasibility of interlayers in Resistance Spot Welding of low-carbon steel sheets |
| title_short | Investigating feasibility of interlayers in Resistance Spot Welding of low-carbon steel sheets |
| title_sort | investigating feasibility of interlayers in resistance spot welding of low carbon steel sheets |
| topic | Resistance Spot Welding Interlayer Feasibility Tensile-Shear strength Electrode Corrosion |
| url | https://doi.org/10.1007/s42452-021-04730-1 |
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