NUMERICAL ANALYSIS OF THE EFFECT OF HEAT INPUT IN THE SPOT WELDING OF DISSIMILAR MATERIALS
Keywords:
resistance spot welding, numerical analysis, heat utilization, nugget growth, Schaeffler diagram
Abstract
Resistance spot welding (RSW) of dissimilar metals is an emerging trend in automobile industries in the manufacture of passenger-vehicle bodies. It provides the material characteristics and advantages of both metals. In this research work, the influence of heat addition and maximum interface temperature in the RSW of austenitic stainless-steel sheets (AISI 304 and AISI 316L) is investigated by welding the specimens at various levels of welding current and weld time. The ultimate strength of the spot-welded joints is analyzed to evaluate the amount of heat utilization and the quality of spot welds, finite-element analysis, and macrostructural evaluations. The thermal distribution profile and stress-strain analysis on the welded specimens are carried out with the 3D finite-element model developed using ABAQUS V6.6 software through incremental electro-thermal-structural analysis. A maximum tensile shear failure strength of 253 MPa was obtained with a nugget diameter 6.55 mm and the heat utilization being 59.69 %.
References
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21. Zeng Liu, Chenglei Fan, Chao Chen, Zhu Ming, Chunli Yang, Sanbao Lin, Langping Wang,
Design and evaluation of nitrogen-rich welding wires for high nitrogen stainless steel,Journal of Materials Processing Technology, Volume 288, 2021,116885.
22. P.Marashi, M.Pouranvari, S.Amirabdollahian, A.Abedi, M.Goodarzi, Microstructure and failure behavior of dissimilar resistance spot welds between low carbon galvanized and austenitic stainless steels. Mat Sci Eng A-Struct. 480(1-2) (2008)175-180
2. T.Jagadeesha, T.J.Sarvoththama Jothi, Studies on the influence of process parameters on the AISI 316L resistance spot-welded specimens, Int J Adv Manuf Tech. 93(1-4) (2017) 73-88.
3.M.Tamizi, M.Pouranvari, M.Movahedi, Welding metallurgy of martensitic advanced high strength steels during resistance spot welding. Sci. Technol. Weld. Joining. 22(4) (2017) 327-335.
4. X .Luo, J.Ren, D.Li, Y.Qin, P.Xu, Macro characteristics of dissimilar high strength steel resistance spot welding joint, Int J Adv Manuf Tech. 87(1-4) (2016) 1105–1113.
5. J.Wang, H.Wang, F.Lu, B.Carlson, D.Sigler, Analysis of Al-steel resistance spot welding process by developing a fully coupled multi-physics simulation model, Int J Heat Mass Tran. 89(2015) 1061-1072.
6.M.Vigneshkumar, P.Ashoka Varthanan, Comparison of RSM and ANN model in the prediction of the tensile shear failure load of spot welded AISI 304/316 L dissimilar sheets, Int J Comput Mater Sci Surf Eng, 8 (2) (2019) 114–130.
7.M.Vigneshkumar, P.Ashoka Varthanan, Y.Maria Ambrose Raj, Finite Element-Based Parametric Studies of Nugget Diameter and Temperature Distribution in the Resistance Spot Welding of AISI 304 and AISI 316L Sheets, Transactions of the Indian Institute of metals, vol. 72(2) 2019 429-438.
8.J.E.Gould, An examination of nugget development during spot welding using both experimental and analytical techniques, Weld J. 66(1) (1987) 01–10.
9 E.Feulvarch, V.Robin, J.M.Bergheau Resistance spot welding simulation: a general finite element formulation of electro thermal contact conditions, J Mater Process Technol 153–154 (2004) 436–441.
10. K.Vignesh, A.Elaya perumal, P.Velmurugan, Resistance spot welding of AISI-316L SS and 2205 DSS for predicting parametric influences on weld strength – Experimental and FEM approach. Archives of civil and mechanical engineering, 19(4) (2019) 1029-1042.
11 Z.Hou, I.Kim, Y.Wang, Li C, Chen C Finite element analysis for the mechanical features of resistance spot welding process. J. Mater. Process. Technol. 185 (2007)160–165.
12 B.Wang, L.Hua, X.Wang, Y.Song, Y.Liu, Effects of electrode tip morphology on resistance spot welding quality of DP590 dual-phase steel, Int J Adv Manuf Tech. 83(9-12) (2016) 1917–1926.
13 H.Moshayedi, I.Sattari-far, Numerical and experimental study of nugget size growth in resistance spot welding of austenitic stainless steels. J Mater Process Tech. 212 (2012) 347-354.
14 Jin Qiang Tan, Mei Zhan, Shuai Liu, Tao Huang, Jing Guo, He Yang, A modified Johnson–Cook model for tensile flow behaviors of 7050-T7451 aluminum alloy at high strain rates, Materials Science and Engineering: A, Volume 631, 2015, Pages 214-219.
15. A. Banerjee, S. Dhar, S. Acharyya, D. Datta, N. Nayak, Determination of Johnson cook material and failure model constants and numerical modelling of Charpy impact test of armour steel, Materials Science and Engineering: A, Volume 640, 2015, Pages 200-209.
16 Farahani, H.K., Ketabchi, M. & Zangeneh, S. Determination of Johnson–Cook Plasticity Model Parameters for Inconel718. J. of Materi Eng and Perform 26, 5284–5293 (2017). https://doi.org/10.1007/s11665-017-2990-2
17. E.A. Flores-Johnson, O. Muransky, C.J. Hamelin, P.J. Bendeich , L. Edwards , Numerical Analysis of the effect of weld-induced residual stress and plastic damage on the ballistic performance of welded steel plate, Comput. Mater. Sci, 58 (2012) 131-139.
18. P. Krasauskas, S. Kilikevicius, R. Cesnavicius, D. Pacenga , Experimental Analysis and numerical simulation of the stainless AISI 304 steel friction drilling process, MECHANIKA, 20(6) 590−595.
19. Wittig, B., Zinke, M., Jüttner, S. et al. A new constitution diagram for dissimilar metal welds of high-manganese steels. Weld World 63, 491–499 (2019). https://doi.org/10.1007/s40194-018-0668-5
20.Raudhah Othman, Thomas Dorin, Nikki Stanford & Peter Hodgson (2022) The microstructure of high manganese TWIP steels produced via simulated direct strip casting, Materials Science and Technology, 38:1, 30-38, DOI: 10.1080/02670836.2021.2021501
21. Zeng Liu, Chenglei Fan, Chao Chen, Zhu Ming, Chunli Yang, Sanbao Lin, Langping Wang,
Design and evaluation of nitrogen-rich welding wires for high nitrogen stainless steel,Journal of Materials Processing Technology, Volume 288, 2021,116885.
22. P.Marashi, M.Pouranvari, S.Amirabdollahian, A.Abedi, M.Goodarzi, Microstructure and failure behavior of dissimilar resistance spot welds between low carbon galvanized and austenitic stainless steels. Mat Sci Eng A-Struct. 480(1-2) (2008)175-180
Published
2022-06-07
How to Cite
1.
Murugesan V, Varthanan PA, Murugan SS, Gokilakrishnan G. NUMERICAL ANALYSIS OF THE EFFECT OF HEAT INPUT IN THE SPOT WELDING OF DISSIMILAR MATERIALS. MatTech [Internet]. 2022Jun.7 [cited 2024Dec.10];56(3):307–313. Available from: https://mater-tehnol.si/index.php/MatTech/article/view/411
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