MICROSTRUCTURE AND PROPERTIES OF 6082/7075 MAGNETIC-FIELD-ASSISTED RESISTANCE-SPOT-WELDED JOINTS
Keywords:
aluminum alloys, thermal compensation, magnetic-field-assisted resistance spot welding, properties
Abstract
To advance automotive lightweighting, a study was conducted on steady-state magnetic-field-assisted resistance spot welding of 6082 aluminum alloy (1.0 mm thick) and 7075 aluminum alloy (1.5 mm thick) with thermal compensation. The influence of varying magnetic induction intensity on the microstructure and tensile properties of welded joints was assessed under the same welding current, time and electrode pressure. The results revealed that the Lorentz force induced by magnetic induction intensity ranging from 0 mT to 60 mT could promote an outward circumferential movement of molten metal within the weld nugget. This movement, at the same time, led to an increase in the weld-nugget size and improved the efficiency of thermal resistance. At a magnetic induction intensity of 80 mT, no weld-nugget formation occurred in the welded joint. Microstructural observations at magnetic induction intensities of 0 mT and 60 mT revealed equiaxed grains at the nugget center and columnar dendrite grains at the nugget edge in the welded joints. The Lorentz force accelerated the weld cooling rates after the addition of magnetic field, refining the weld grain structure. Tensile properties of the welded joints gradually improved with increasing the magnetic induction intensity from 0 mT to 60 mT, driven by the weld nugget size expansion and weld grain refinement. Overall, the present study indicated that the magnetic induction intensity of 60 mT resulted in the most favorable comprehensive mechanical properties of the investigated welded joints.
References
REFERENCES
[1] Taub A , De Moor E , Luo A ,et al.Materials for Automotive Lightweighting[J].Annual Review of Materials Research, 2019, 49:327-359.DOI:10.1146/annurev-matsci-070218-010134.
[2] Ambroziak, A., Korzeniowski, M. Using resistance spot welding for joining aluminum elements in automotive industry. Archiv.Civ.Mech.Eng 10, 5–13 (2010). https://doi.org/10.1016/S1644-9665(12)60126-5
[3] Manladan, S.M., Yusof, F., Ramesh, S. et al. A review on resistance spot welding of aluminum alloys. Int J Adv Manuf Technol 90, 605–634 (2017). https://doi.org/10.1007/s00170-016-9225-9
[4] Zhang WJ, Cross I, Feldman P, Rama S, Norman S, Del Duca M. Electrode life of aluminum resistance spot welding in automotive applications: a survey. Science and Technology of Welding and Joining. 2017;22(1):22-40. doi:10.1080/13621718.2016.1180844
[5] Bi J , Song J L , Wei Q ,et al.Characteristics of shunting in resistance spot welding for dissimilar unequal-thickness aluminum alloys under large thickness ratio[J].Materials & Design, 2016, 101(JUL.5):226-235.DOI:10.1016/j.matdes.2016.04.023.
[6] Lee T. Resistance spot weldability of heat-treatable and non-heat-treatable dissimilar aluminum alloys. Science and Technology of Welding and Joining. 2020;25(7):543-548. doi:10.1080/13621718.2020.1761619
[7] Piott, M., Werber, A., Schleuss, L. et al. Numerical and experimental analysis of heat transfer in resistance spot welding process of aluminum alloy AA5182. Int J Adv Manuf Technol 111, 1671–1682 (2020). https://doi.org/10.1007/s00170-020-06197-7
[8] Shamim FA, Dvivedi A, Kumar P. Fabrication and characterization of Al6063/SiC composites using electromagnetic stir casting process. Proceedings of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering. 2022;236(1):187-193. doi:10.1177/09544089211045796
[9] Yin, Sk., Luo, S., Zhang, Wj. et al. Numerical simulation of macrosegregation in continuously cast gear steel 20CrMnTi with final electromagnetic stirring. J. Iron Steel Res. Int. 28, 424–436 (2021). https://doi.org/10.1007/s42243-020-00490-1
[10] Liu L , Zhu Y , Liu R .Study of twin tungsten electrode – wire electrode indirect arc welding assisted by alternating magnetic field[J].Journal of Manufacturing Processes, 2023.DOI:10.1016/j.jmapro.2023.06.007.
[11] Chen J, Chen Q, Wu C. Study of high-speed pulsed gas metal arc welding assisted by external magnetic-field. Science and Technology of Welding and Joining. 2020;25(7):564-570. doi:10.1080/13621718.2020.1774994
[12] Zhan X , Liu X , Li Y ,et al.Molten pool behavior and solidification characterization in steady magnetic field assisted laser-MIG hybrid welding of aluminum alloy[J].Journal of manufacturing processes, 2022.
[13] Li, L., Huang, C., Han, G. et al. Recent progress on external magnetic field assisted laser welding: mechanism, effect and technology. Int J Adv Manuf Technol 125, 1–23 (2023). https://doi.org/10.1007/s00170-022-10653-x
[14] Shanqing Hu, Amberlee S. Haselhuhn, Yunwu Ma, Zhuoran Li, Lin Qi, Yongbing Li, Blair E. Carlson & Zhongqin Lin (2022) Effect of external magnetic field on resistance spot welding of aluminum to steel, Science and Technology of Welding and Joining, 27:2, 84-91, DOI: 10.1080/13621718.2021.2013707
[15] Lin Qi, Qingxin Zhang, Sizhe Niu, Ruiming Chen & Yongbing Li (2021) Influencing mechanism of an external magnetic field on fluid flow, heat transfer and microstructure in aluminum resistance spot welding, Engineering Applications of Computational Fluid Mechanics, 15:1, 985-1001, DOI: 10.1080/19942060.2021.1938684
[16] Tao Xu, Yonghua Shi, Yanxin Cui, Zhuoyong Liang, Effects of Magnetic Fields in Arc Welding, Laser Welding, and Resistance Spot Welding: A Review , 5(25): 2200682
https://doi.org/10.1002/adem.202200682
[17] B L Q A , C F L , B R C A ,et al.Improve resistance spot weld quality of advanced high strength steels using bilateral external magnetic field[J].Journal of Manufacturing Processes, 2020, 52:270-280.DOI:10.1016/j.jmapro.2020.02.030.
[18] Li YB, Zhang QX, Qi L, David SA. Improving austenitic stainless steel resistance spot weld quality using external magnetic field. Science and Technology of Welding and Joining. 2018;23(7):619-627. doi:10.1080/13621718.2018.1443997
[19] Y. B. Li, D. L. Li, S. A. David, Y. C. Lim & Z. Feng (2016) Microstructures of magnetically assisted dual-phase steel resistance spot welds, Science and Technology of Welding and Joining, 21:7, 555-563, DOI: 10.1080/13621718.2016.1141493
[20] Huang M , Zhang Q , Qi L ,et al.Effect of external magnetic field on resistance spot welding of aluminum alloy AA6061-T6[J].Journal of Manufacturing Processes, 2020, 50:456-466.DOI:10.1016/j.jmapro.2020.01.005.
[21] Qi L , Zhang Q , Ma Y ,et al.A comparative study on mechanical performance of traditional and magnetically assisted resistance spot welds of A7N01 aluminum alloy[J].Journal of Manufacturing Processes, 2021, 66(4):133-144.DOI:10.1016/j.jmapro.2021.04.006.
[22] Wei H , Chen J S , Wang H P ,et al.Thermomechanical numerical analysis of hot cracking during laser welding of 6XXX aluminum alloys[J].Journal of Laser Applications, 2016, 28(2):022405.DOI:10.2351/1.4944005.
[23] Xin Z , Yang Z , Zhao H ,et al.Comparative Study on Welding Characteristics of Laser-CMT and Plasma-CMT Hybrid Welded AA6082-T6 Aluminum Alloy Butt Joints[J].Materials, 2019, 12(20):3300-.DOI:10.3390/ma12203300.
[24] S,C,Wu,et al.Porosity induced fatigue damage of laser welded 7075-T6 joints investigated via synchrotron X-ray microtomography[J].Science and Technology of Welding and Joining, 2015, 20(1):11-19.DOI:10.1179/1362171814Y.0000000249.
[25] Qiu R , Shi H , Yu H ,et al.Joining phenomena of stainless steel/aluminum alloy joint welded by thermal compensation resistance spot welding[J].International Journal of Materials and Product Technology, 2014, 49(4):285.DOI:10.1504/IJMPT.2014.064939.
[26] Wu Sainan, Jia Zhihong, GHAFFARI Bita, et al. Microstructure and mechanical properties of resistance spot welding joint of AA5754 aluminum alloy [J]. Journal of Central South University (Natural Science Edition), 2018.doi: 10.19476/j.ysxb.1004.0609.2018.04.
[27] JIA Zhi-hong, DING Li-peng, WU Sai-nan, WANG Xue-li, LIU Qing, CHEN Chang-yun. Research progress on microstructure and heat treatment of 6000 series aluminum alloys sheet for
automotive body[J]. Journal of Materials Engineering, 2014(12):104−113. DOI:10.11868/j.issn.1001-4381.2014.12.018.
[1] Taub A , De Moor E , Luo A ,et al.Materials for Automotive Lightweighting[J].Annual Review of Materials Research, 2019, 49:327-359.DOI:10.1146/annurev-matsci-070218-010134.
[2] Ambroziak, A., Korzeniowski, M. Using resistance spot welding for joining aluminum elements in automotive industry. Archiv.Civ.Mech.Eng 10, 5–13 (2010). https://doi.org/10.1016/S1644-9665(12)60126-5
[3] Manladan, S.M., Yusof, F., Ramesh, S. et al. A review on resistance spot welding of aluminum alloys. Int J Adv Manuf Technol 90, 605–634 (2017). https://doi.org/10.1007/s00170-016-9225-9
[4] Zhang WJ, Cross I, Feldman P, Rama S, Norman S, Del Duca M. Electrode life of aluminum resistance spot welding in automotive applications: a survey. Science and Technology of Welding and Joining. 2017;22(1):22-40. doi:10.1080/13621718.2016.1180844
[5] Bi J , Song J L , Wei Q ,et al.Characteristics of shunting in resistance spot welding for dissimilar unequal-thickness aluminum alloys under large thickness ratio[J].Materials & Design, 2016, 101(JUL.5):226-235.DOI:10.1016/j.matdes.2016.04.023.
[6] Lee T. Resistance spot weldability of heat-treatable and non-heat-treatable dissimilar aluminum alloys. Science and Technology of Welding and Joining. 2020;25(7):543-548. doi:10.1080/13621718.2020.1761619
[7] Piott, M., Werber, A., Schleuss, L. et al. Numerical and experimental analysis of heat transfer in resistance spot welding process of aluminum alloy AA5182. Int J Adv Manuf Technol 111, 1671–1682 (2020). https://doi.org/10.1007/s00170-020-06197-7
[8] Shamim FA, Dvivedi A, Kumar P. Fabrication and characterization of Al6063/SiC composites using electromagnetic stir casting process. Proceedings of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering. 2022;236(1):187-193. doi:10.1177/09544089211045796
[9] Yin, Sk., Luo, S., Zhang, Wj. et al. Numerical simulation of macrosegregation in continuously cast gear steel 20CrMnTi with final electromagnetic stirring. J. Iron Steel Res. Int. 28, 424–436 (2021). https://doi.org/10.1007/s42243-020-00490-1
[10] Liu L , Zhu Y , Liu R .Study of twin tungsten electrode – wire electrode indirect arc welding assisted by alternating magnetic field[J].Journal of Manufacturing Processes, 2023.DOI:10.1016/j.jmapro.2023.06.007.
[11] Chen J, Chen Q, Wu C. Study of high-speed pulsed gas metal arc welding assisted by external magnetic-field. Science and Technology of Welding and Joining. 2020;25(7):564-570. doi:10.1080/13621718.2020.1774994
[12] Zhan X , Liu X , Li Y ,et al.Molten pool behavior and solidification characterization in steady magnetic field assisted laser-MIG hybrid welding of aluminum alloy[J].Journal of manufacturing processes, 2022.
[13] Li, L., Huang, C., Han, G. et al. Recent progress on external magnetic field assisted laser welding: mechanism, effect and technology. Int J Adv Manuf Technol 125, 1–23 (2023). https://doi.org/10.1007/s00170-022-10653-x
[14] Shanqing Hu, Amberlee S. Haselhuhn, Yunwu Ma, Zhuoran Li, Lin Qi, Yongbing Li, Blair E. Carlson & Zhongqin Lin (2022) Effect of external magnetic field on resistance spot welding of aluminum to steel, Science and Technology of Welding and Joining, 27:2, 84-91, DOI: 10.1080/13621718.2021.2013707
[15] Lin Qi, Qingxin Zhang, Sizhe Niu, Ruiming Chen & Yongbing Li (2021) Influencing mechanism of an external magnetic field on fluid flow, heat transfer and microstructure in aluminum resistance spot welding, Engineering Applications of Computational Fluid Mechanics, 15:1, 985-1001, DOI: 10.1080/19942060.2021.1938684
[16] Tao Xu, Yonghua Shi, Yanxin Cui, Zhuoyong Liang, Effects of Magnetic Fields in Arc Welding, Laser Welding, and Resistance Spot Welding: A Review , 5(25): 2200682
https://doi.org/10.1002/adem.202200682
[17] B L Q A , C F L , B R C A ,et al.Improve resistance spot weld quality of advanced high strength steels using bilateral external magnetic field[J].Journal of Manufacturing Processes, 2020, 52:270-280.DOI:10.1016/j.jmapro.2020.02.030.
[18] Li YB, Zhang QX, Qi L, David SA. Improving austenitic stainless steel resistance spot weld quality using external magnetic field. Science and Technology of Welding and Joining. 2018;23(7):619-627. doi:10.1080/13621718.2018.1443997
[19] Y. B. Li, D. L. Li, S. A. David, Y. C. Lim & Z. Feng (2016) Microstructures of magnetically assisted dual-phase steel resistance spot welds, Science and Technology of Welding and Joining, 21:7, 555-563, DOI: 10.1080/13621718.2016.1141493
[20] Huang M , Zhang Q , Qi L ,et al.Effect of external magnetic field on resistance spot welding of aluminum alloy AA6061-T6[J].Journal of Manufacturing Processes, 2020, 50:456-466.DOI:10.1016/j.jmapro.2020.01.005.
[21] Qi L , Zhang Q , Ma Y ,et al.A comparative study on mechanical performance of traditional and magnetically assisted resistance spot welds of A7N01 aluminum alloy[J].Journal of Manufacturing Processes, 2021, 66(4):133-144.DOI:10.1016/j.jmapro.2021.04.006.
[22] Wei H , Chen J S , Wang H P ,et al.Thermomechanical numerical analysis of hot cracking during laser welding of 6XXX aluminum alloys[J].Journal of Laser Applications, 2016, 28(2):022405.DOI:10.2351/1.4944005.
[23] Xin Z , Yang Z , Zhao H ,et al.Comparative Study on Welding Characteristics of Laser-CMT and Plasma-CMT Hybrid Welded AA6082-T6 Aluminum Alloy Butt Joints[J].Materials, 2019, 12(20):3300-.DOI:10.3390/ma12203300.
[24] S,C,Wu,et al.Porosity induced fatigue damage of laser welded 7075-T6 joints investigated via synchrotron X-ray microtomography[J].Science and Technology of Welding and Joining, 2015, 20(1):11-19.DOI:10.1179/1362171814Y.0000000249.
[25] Qiu R , Shi H , Yu H ,et al.Joining phenomena of stainless steel/aluminum alloy joint welded by thermal compensation resistance spot welding[J].International Journal of Materials and Product Technology, 2014, 49(4):285.DOI:10.1504/IJMPT.2014.064939.
[26] Wu Sainan, Jia Zhihong, GHAFFARI Bita, et al. Microstructure and mechanical properties of resistance spot welding joint of AA5754 aluminum alloy [J]. Journal of Central South University (Natural Science Edition), 2018.doi: 10.19476/j.ysxb.1004.0609.2018.04.
[27] JIA Zhi-hong, DING Li-peng, WU Sai-nan, WANG Xue-li, LIU Qing, CHEN Chang-yun. Research progress on microstructure and heat treatment of 6000 series aluminum alloys sheet for
automotive body[J]. Journal of Materials Engineering, 2014(12):104−113. DOI:10.11868/j.issn.1001-4381.2014.12.018.
Published
2024-08-19
How to Cite
1.
Zhu X, Liu Z, Yin G, Li Y. MICROSTRUCTURE AND PROPERTIES OF 6082/7075 MAGNETIC-FIELD-ASSISTED RESISTANCE-SPOT-WELDED JOINTS. MatTech [Internet]. 2024Aug.19 [cited 2025May16];58(4):451–457. Available from: https://mater-tehnol.si/index.php/MatTech/article/view/1144
Section
Articles
