process settings
Optimization of Resistance Spot Welding
Resistance spot welding (RSW) is widely used for joining sheet metal components. It operates with three process parameters: current, force, and time. However, a good weld can only be made within a certain range of parameter combinations. Below the lower limit, no weld can be made. Above the upper limit, there will be expulsions. This … Continue readingFalse weld (cold weld)
Cold weld (false weld) means no proper weld nugget formed during the resistance welding process. It is one of the most common weldability problems in the automotive industry in multi-sheet spot welding with dissimilar materials. Increasing false welds can harm the safety of the cars drastically or the production line must stop and rerun. 2 … Continue readingWeld splash
Weld splash (expulsion/spatter) happens when molten material comes out from the weld nugget. It causes cosmetic problems, defective welds, safety issues for workers, and maintenance problems in the production line. Weld splash is one of the most common issues in the welding industry. Why does weld splash happen? There are many causes of splashes. The … Continue readingGap between sheets
Gap between welding parts can cause unstable welding production. It can lead to early splash or no weld due to bad contact or improper gap closure. This case study shows how the gap size affects the splash limit and the lower limit of process window by using SORPAS simulation.
Process window and strength of steels
The weldability of material is different from each other. It also means each material has its own process windows.