The influence of the machine specific instantaneous current wave forms on weld nugget dimensions and weld strength is investigated over six spot welding machines. It is observed that the nature of the real-time current wave forms corresponding to a common rms value can vary in different ac spot welding machines. The variations exist in the values of peak current and in the current-on and -off times in every ac cycle. It is observed that real-time current wave form involving higher peak current leads to slightly larger weld nugget diameter compared to wave form with smaller peak current even if the overall rms value remains similar. The real-time current wave form from a medium frequency dc confirms to a fast rise to the set weld current and remains steady for the complete weld time. A detailed experimental study has depicted that the real-time ac wave forms especially with high peak values and sharp rise characteristics offer a relatively smaller permissible range of weld currents compared to the wave forms with relatively flatter characteristics. The steady instantaneous current wave form confirming to the medium frequency dc machine has facilitated a larger permissible range of weld current. A numerical analysis of the spot welding process based on finite element process is carried out using both the instantaneous current wave forms and the corresponding rms values of weld current. The predicted weld dimensions using instantaneous current wave forms have showed slightly better agreement with the corresponding measured weld dimensions.
Skip Nav Destination
Article navigation
August 2006
Technical Papers
Influence of Machine Specific Instantaneous Current Wave Form on Resistance Spot Welding Process
K. Momeni,
K. Momeni
Institute for Joining and Coating Engineering
, TU Berlin, Berlin 10587, Germany
Search for other works by this author on:
M. P. Thaddeus,
M. P. Thaddeus
Mechanical Engineering Department
, IIT Bombay, Mumbai, Maharashtra, India
Search for other works by this author on:
L. Dorn
L. Dorn
Professor
Institute for Joining and Coating Engineering
, TU Berlin, Berlin 10587, Germany
Search for other works by this author on:
A. De
Associate Professor
K. Momeni
Institute for Joining and Coating Engineering
, TU Berlin, Berlin 10587, Germany
M. P. Thaddeus
Mechanical Engineering Department
, IIT Bombay, Mumbai, Maharashtra, India
L. Dorn
Professor
Institute for Joining and Coating Engineering
, TU Berlin, Berlin 10587, GermanyJ. Manuf. Sci. Eng. Aug 2006, 128(3): 668-676 (9 pages)
Published Online: December 2, 2005
Article history
Received:
June 5, 2005
Revised:
December 2, 2005
Citation
De, A., Momeni, K., Thaddeus, M. P., and Dorn, L. (December 2, 2005). "Influence of Machine Specific Instantaneous Current Wave Form on Resistance Spot Welding Process." ASME. J. Manuf. Sci. Eng. August 2006; 128(3): 668–676. https://doi.org/10.1115/1.2164507
Download citation file:
Get Email Alerts
Cited By
A Study on the Influence of Polypropylene Melt Flow Index on Nonwoven Fibers Produced Through Hot Melt Centrifugal Spinning
J. Manuf. Sci. Eng (April 2025)
Arc Characteristics of Aluminum Alloy Double-Wire High-Frequency Pulsed GMAW
J. Manuf. Sci. Eng (April 2025)
Related Articles
A Comparative Study of Single-Phase AC and Multiphase DC Resistance Spot Welding
J. Manuf. Sci. Eng (August,2005)
Modeling and On-Line Estimation of Electrode Wear in Resistance Spot Welding
J. Manuf. Sci. Eng (November,2005)
Effect of Forging Force on Fatigue Behavior of Spot Welded Joints of Aluminum Alloy 5182
J. Manuf. Sci. Eng (February,2007)
Monitoring Resistance Spot Nugget Size by Electrode Displacement
J. Manuf. Sci. Eng (May,2004)
Related Proceedings Papers
Related Chapters
Defining Joint Quality Using Weld Attributes
Ultrasonic Welding of Lithium-Ion Batteries
Subsection NE—Class MC Components
Online Companion Guide to the ASME Boiler & Pressure Vessel Codes
LOW STRAIN CAPACITY GIRTH WELDS OF NEWLY CONSTRUCTED PIPELINES AND MITIGATIVE APPROACHES
Pipeline Integrity Management Under Geohazard Conditions (PIMG)