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Applications

The major industrial sectors applying resistance welding are listed below.
 

  • Automotive / auto industry 
  • Aerospace / air plane 
  • Train carriage / rail
  • Electrical / electronics
  • Radiator / container
  • Domestic hardware
  • Medical instruments
  • Nuclear equipment
  • Food and drink, etc.
Resistance welding applications
SORPAS® is tailor-made welding software for simulation and optimization of resistance welding processes. It has been commercialized since 2000 and now applied by many companies in various industrial sectors all over the world. It supports research and development, weldability evaluation, welding process parameter optimization, production line building and planning, as well as maintenance in resistance welding including spot welding and projection welding etc.

Below are some examples for industrial applications of the software.


Welding process simulation:

Resistance spot welding:   Resistance projection welding:
Resistance spot welding Resistance projection welding - Click for Animation...
 
Temperature development and weld nugget formation in spot welding of three sheets, one 1 mm TRIP steel to two 2 mm mild steel, with three pulse AC. Temperature development, collapse of projection and weld nugget formation in embossed projection welding of galvanized steel with up-slope AC.
 
Resistance butt welding: Micro resistance welding:
Resistance butt welding - Click for Animation... Micro resistance welding - Click for Animation...
 

Temperature development, deformation of parts and weld nugget formation in resistance butt welding of steel plates with AC.

Temperature development and nugget formation in micro series welding of nickel sheet to nickel coated steel with two pulse DC.


Welding process parameter optimization:

With the Enterprise Edition , several functions for automated simulations have been developed to support welding process parameter optimization. It is possible to run fully automated procedures to generate the weld growth curves and the weldability lobes.

Weld growth curve for resistance spot welding

This is a weld growth curve generated automatically with SORPAS® for spot welding of 1 mm mild steel sheets in the range of weld current from 2 kA to 16 kA. The software has automatically identified the working range with green color points indicating the good spot welds, the red color points indicating splashes and the black color points indicating no weld.

Weldability lobe for resistance spot welding

This is a weldability lobe generated automatically with SORPAS® for spot welding of 1 mm mild steel sheets with two welding process parameters (weld current and time) referring to ISO 14327:2004. Three reference weld nugget diameters (minimum, maximum and nominal) are indicated. It is also possible to generate the weldability lobe with weld current and force.


Report of simulation:

After each simulation, SORPAS® will generate a Report of Simulation for documentation. Below is a typical report for a spot welding simulation. In the upper part, it shows the initial welding conditions including material combinations, geometry of electrodes and workpieces as well as the welding process parameter settings. In the lower part, it shows the main simulation results with a selected process parameter curve, the final temperature distribution with the weld nugget dimension in each workpiece.

Simulation report for resistance spot welding

 

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