Weld Producing

< Key Principle > To make sure the welding production running under control and foresee potential problems to take predictive actions.

< Real Problem > Inconsistent weld quality and unexpected welding problem with unknown root cause hence difficult to find a quick solution.

< Digital Solution > Find root causes of welding problems by simulations with possible process tolerances and irregular welding conditions.

Production maintenance

When the welding production has started with systematically optimized process parameters well planned in the optimal process window, the problems arising during the welding production would be mostly due to unintended changes in welding conditions, for example electrode degradation, gap between sheets, electrode misalignment, and possibly errors from preceding processes such as the temperature history of hot pressing and heat treatment.

Production maintenance increases the weld quality, production stability, and productivity.

One of the most common issues is to reduce spatter (splash or expulsion).

SORPAS can help to optimize the welding process thus reducing the spatter…

Irregular conditions

sorpas 3d model for gap between metal sheets

Gap between workpieces

It is quite common during the welding production, there may be gap between sheets before starting spot welding, mainly due to the process tolerances in the preceding stamping process, stamping or sheet forming. This will need special process parameter settings to close the gap between sheets before starting the weld current. It can be done by prolonging the squeeze time, slightly increase the electrode force during squeeze time, or by using a preheating pulse with lower current before the weld current.

Gap with symmetry can be simulated by SORPAS® 2D.welding and more effectively simulated by SORPAS 3D.welding for any asymmetrical model.

sorpas 3d model for electrode misalignment

Electrode misalignment

Due to mounting errors or elastic deflection of the weld gun during spot welding, the electrodes are quite often not perfectly aligned to each other. The electrodes may be tilted with a small angle to each other, or may be offside with a small distance between the contacting centers of the two electrodes. The electrode alignment may produce irregular weld nuggets or cause severe expulsions (spatter, splash). SORPAS 3D.welding can simulate the effect of electrode misalignment in all situations.

Preceding process

heating material in furnace

Hot stamping

Numerous automotive parts, especially for the safety components are produced by hot stamping technology today. The high strength at the final stage and the good plastic formability after heating is the main benefits of this technology.

But welding on hot stamped parts can be tricky, since heat treatment process effects the properties of base material and surface coating.

For example, intermetallic alloying reaction between the Al-Si coating and the iron of the sheet material takes place during heating process in the furnace. As a result the electrical resistance of AlSi coating increases after heat treatment. Higher resistance influences the current and nugget formation in the welding process.
In case of projection welding of fasteners, the huge hardness gap between the fasteners and the hot stamped base material causes the projections to collapse before a good weld is achieved.