Root Cause Analysis of Resistance Welding Problems
All root causes can be classified into three categories: design factors, process settings, and dynamic issues. Find our guidelines for detecting root causes and finding solutions.
For over 25 years, SORPAS® has been the trusted intelligence in resistance welding – helping automotive OEMs and Tier-1 suppliers worldwide. For OEMs, it means consistent quality with stronger joints, fewer prototypes, and faster launches. For Tier-1 suppliers, it’s a competitive edge with faster RFQs, less scrap, and more uptime.
Born as a welding simulation tool, SORPAS® predicts weld quality, nugget size and weld strength before a single weld is made. Now, it’s more than just simulation. The digital optimizations can automatically deliver optimized, production-ready parameters that balance quality, robustness, and electrode life. Today, early stage digital twins are being developed for analyzing live welding data, detecting process drift, and tracking KPIs for each weld – paving the way for predictive maintenance and future smart factories.
Digital Transformation of Welding for Industry 4.0
The rapid transition to electric vehicles (EVs) has driven many technological developments in automotive and related industries. Simulation, digital optimizations and digital twins for welding are continuously developed and increasingly applied through all stages of welding production lifecycle from design and pre-production planning to production optimizations for stabilizing manufacturing systems.
With continuous innovations and widespread industrial applications over 25 years, SORPAS® has been widely adopted in welding industries worldwide for welding simulations and optimizations. It is used for technology innovation, solving welding problems, predicting weldability of materials, planning weld schedules, optimizing welding process parameters, improving weld quality and predictive production maintenance.
Welding Technology…
Resistance welding, mechanical joining and adhesive bonding are highly productive and cost-effective joining technologies widely applied in manufacturing industry especially in automotive, aerospace, electronics and electrical industries.
Resistance spot welding is predominantly used for joining thin sheets such as assembly of car body-in-white. Resistance projection welding is more used for joining complex or small parts such as nut welding, electronic circuits and electrical connectors. Mechanical joining processes including self-piercing riveting (SPR) and clinching are mostly used for assembly of cars with aluminum sheets, and also for joining dissimilar materials such as aluminum and steel or metal and carbon fiber materials. Adhesive bonding is increasingly used in car body assembly often combining with spot welding or SPR to improve the overall strength and stiffness of the car and crash performance.
These welding and joining technologies are constantly advanced through technological innovations aided with welding simulations and optimizations.
Resistance welding includes spot welding, projection welding, seam welding, butt welding and micro resistance welding…
Mechanical joining includes clinching, riveting, clinch riveting, self-piercing riveting and other joining processes by forming…
Adhesive bonding (also referred to as gluing) is to join materials by applying an intermediate layer of adhesives or glues…
Numerical simulation is a computer technology by using numerical modeling methods to imitate engineering processes…
SWANTEC is an ISO 9001:2015 Certified Company.
SWANTEC is an Affiliate Company Member of the American Welding Society (AWS).
