• Journal of Welding and Joining
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• v.16 no.5
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• pp.76-85
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• 1998

The resistance spot welding process has been used for joining the sheet metal in automotive engineering. In the resistance spot welding, the weld quality is very important, because the quality of weld is one of the most important factors to the automobile quality. The size of he molten nugget has been utilized to estimate the weld quality. However, it is not easy to find the weld defects. For weldability estimation, we have to use the nondestructive method such as X-ray or ultrasonic inspection. But these kinds of approaches are not suitable for detecting the defects in real time. The purpose of this study is to develop the real time monitoring of the weld quality in the resistance spot welding. Obtained data were used to estimate weldability using fuzzy algorithm. It is sound that this monitoring and estimation system can be useful to improve the weld quality in the resistance spot welding process and it is possible to estimate the weldability in real time.

• Transactions of the Korean Society of Mechanical Engineers
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• v.10 no.2
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• pp.241-246
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• 1986

A new method of on-line monitoring of spot weld quality is proposed by analysing weld votage signal. Weld voltage signal has been modeled by autoregressive model which is suitable for on-line modeling scheme, and order of the model is determined by F-test. From the chosen model, strength. Upon experimental results, it has been shown that fundamental frequency dispersion of weld voltage can be used as a good parameter like maximum thermal expansion in on-line monitoring of spot weld quality. Microcomputer implementation of the proposed monitoring method is also developed and presented.

• Journal of Welding and Joining
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• v.12 no.3
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• pp.109-117
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• 1994

Spot welding has wide used with a high work efficiency in the automotive and aerospace industries. Up to the present, the technique mainly used to test spot welds on production lines has been entirely depended upon destructive chisel or peel testing. Therefore, it's being very important assignment to secure the NDE technique which can be evaluate spot weld quality with more efficiency and high reliability. This paper discusses the feasibility of UNDE techniques to evaluate spot weld quality. For the sake of the approach to the quantitative measurement of nugget diameter and the discrimination of a the corona bond from nugget, ultrasonic c-scan image and distribution of reflective echo amplitude was measured by immersion method with the mechanical and the electronic scanning of point-focussed ultrasonic beam(25 MHz). As the results of this study, corona bond which is the most dangerous types of interface defects can be successfully detected, as well as expulsion and voids. Ultrasonic testing results were confirmed and compared by optical microscope and SAM(Scanning Acoustic Microscope) observation of the spot-weld cross section. The results show that the nugget diameter can be successfully measured with the accuracy of 0.8 mm.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.22 no.3
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• pp.644-653
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• 1998

In resistance spot weld, the assurance of weld quality has been a long-standing problem. Since the weld nuggets if resustance spot welding form between the workpieces, visual detection of defects in usually impossible. Welding quality of resistance spot welding can be verified by non destructive and destructive inspections such as X-Ray inspection and testing of weld strength. But these tests, in addition to being time-consuming and costly, can entail risks due to sampling basis. The purpose of this study is the development of the monitoring system based on fuzzy inference, aimed at diagonosis of quality in resistance spot welding. The fuzzy inference system consists of fuzzy input variables, fuzzy membership functions and fuzzy rules. For inferring the welding quality(strength), the experimental data of the spot welding were acquired in various welding conditions with the monitoring system designed. Some fuzzy input variables-maximum, slop and difference values of electrode movement signals-were extracted from the experimental data. It was confirmed that the fuzzy inference values of strength have a .${\pm}$5% error in comparison with actual values for the selected welding conditions(9-10.5KA, 10-14 cycle, 250-300 $kg_f$). This monitoring system can be useful in improving the quality assurance and reliability of the resistance spot welding process.

• Proceedings of the KIPE Conference
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• 1998.07a
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• pp.143-148
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• 1998

A dynamic electrical parameter monitoring device was designed to simultaneously record the instantaneous value of voltage, current, power, and resistance during spot welding. The data obtained using this technique have been analyzed in term of the relationships of these parameters to the phenomena occuring during the formation(surface break-down, nugget formation and mechanical collapse) of spot weld. Finally, a database implementation is undertaken to develop techniques for improving weld quality of the resistance spot welder.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.5 no.4
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• pp.38-46
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• 1996

This paper discusses the feasibility of Ultrasonic Nondestructive Evaluation (UNDE) technique for sport weld quality. Ultrasonic c-scan image assisted by image processing technique was used for Nondestructive Evaluation(NDE) of spot weld quality. Ultrasonic testing results obtained were confirmed and compared by Optical Microscope and SAM(Scanning Acoustic Mircroscope) observation of the spot-weld cross section, The results show that the nugget dinameter can be successfully measured with the accuracy of 0.5mm. It was ascertained that ultrasonic c-scan technique is very effective method for the sake of the approach to the quantitative measurement of nugget diameter and the discrimination of the corona bond from nugget. Additional support for the above conclusions is provided by the results for galvanized steel. The ultrasonic results for galvanized welds generally correspond to the results for uncoated steel. Finally, it was found that the above-mentioned technique can be sufficiently applied to NDE method for securing the Quality Assurance(QA) of spot welded products in production line.

• Journal of Welding and Joining
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• v.29 no.1
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• pp.115-122
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• 2011

This study is to propose an in-process monitoring system for micro resistance spot welding processes using minute accelerometer. A minute accelerometer is mounted on the upper moving electrode tip holder. With its high sensitivity and frequency response characteristics, accelerometer output signal has been successfully recorded and integrated twice to reflect electrode expansion during micro spot welding processes. The analysis of electrode expansion pattern was attempted to find its correlation with spot weld quality. Major previous findings1-6) regarding spot weld quality assessment with the electrode expansion signal in large scale resistance spot welding processes were proved to be true in this in-process monitoring system.

• Journal of Welding and Joining
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• v.17 no.2
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• pp.44-52
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• 1999

This study deals with spot weld ability of dissimilar aluminum alloy sheets in order to take advantage of its lightweight and strength. The paper also shows the relationship between weld elements(i.e. current, welding time and tip force) and weld quality on the resistance spot weld part of the same and dissimilar Al alloy. The conclusions are: (1) Because of excessive tip force, deep indentation remained at the Al 5182 side which is lower stiffness at the dissimilar Al alloy. (2) Weld quality (i.e. tensile shear strength) of dissimilar Al alloy is superior to that of the same Al 6061 alloy. (3) As long cycles, fatigue life of spot weld specimen on dissimilar Al alloy sheets was better than that of the same Al alloy.

• Proceedings of the KWS Conference
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• 2007.11a
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• pp.73-75
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• 2007

The resistance spot weld is among the most common automotive weld method, now a constant current type is the most common used types. A constant current type have a weak point which can not deal with a defect occurrence by external factors, and recently the adaptive resistance spot weld have been applied around the advanced automotive company. This technology can maintain a stable weld quality through a suitable control the current and weld time with weld environment. In this research, the adaptive resistance spot weld is applied to high strength steels, and its application possibility and weld characteristics are presented.

• The Transactions of the Korean Institute of Power Electronics
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• v.20 no.6
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• pp.491-497
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• 2015

This study proposes a new control method for a resistance spot welding inverter to improve weld quality. The proposed method is based on the dynamic resistance characteristics of steel sheets to be welded. A point in the second peak value of the dynamic resistance occurs during one shot of the welding current flow. A constant voltage control is applied from zero to the peak point, and a constant current control is adopted from the peak point to the end of the shot. The mixed mode control of the constant voltage and current guarantees high weld quality. Experiments are conducted with a 5 kA power supply and 0.5 mm steel sheets to compare quality. Experimental results show that weld quality is improved more than 10 times that of the conventional control method.