Influence of initial gap on weld expulsion in resistance spot welding of dual phase steel

The weld expulsion is prone to occur and severely affects the nugget quality when the initial gap between dual phase (DP) steel sheets exist in resistance spot welding (RSW). To investigate the effect of initial gap on weld expulsion, a finite element model was developed to analyse the weld nugget f...

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Bibliographic Details
Published in:Science and technology of welding and joining 2010-07, Vol.15 (5), p.386-392
Main Authors: Shen, J., Zhang, Y. S., Lai, X. M.
Format: Article
Language:English
Subjects:
DUAL PHASE STEEL
Dual phase steels
Expulsion
INITIAL GAP
Low carbon steels
Mathematical models
RESISTANCE SPOT WELDING
Sheet metal
Steels
WELD EXPULSION
Welded joints
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Summary:The weld expulsion is prone to occur and severely affects the nugget quality when the initial gap between dual phase (DP) steel sheets exist in resistance spot welding (RSW). To investigate the effect of initial gap on weld expulsion, a finite element model was developed to analyse the weld nugget formation process with different initial gaps for DP steels. An estimation method of expulsion occurrence based on the ratio of the nugget radius R n and the contact radius R c between sheets was proposed to get the critical initial gap without expulsion. The simulation and experimental results showed that the weld expulsion would not happen until the gap spacing reaches the critical value. The critical initial gap of DP steel is much smaller than that of low carbon steel. For both DP steel and low carbon steel, the critical initial gap would increase with the thickening of the steel sheet.
ISSN:1362-1718
1743-2936
DOI:10.1179/136217110X12693513264213