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Effect of aluminium sheet surface conditions on feasibility and quality of resistance spot welding

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Han, Li, Thornton, Martin, Boomer, Douglas and Shergold, M.. (2010) Effect of aluminium sheet surface conditions on feasibility and quality of resistance spot welding. Journal of Materials Processing Technology, Vol.210 (No.8). pp. 1076-1082. ISSN 0924-0136

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Official URL: http://dx.doi.org/10.1016/j.jmatprotec.2010.02.019...

Abstract

A study investigating the effect of sheet surface condition on resistance spot welding (RSW) of aluminium has been carried out. This concentrates on two automotive aluminium alloys; AA5754 and AA6111, used for structural and closure applications respectively. The results show the marked effect that surface condition can have on the RSW process. For AA5754 sheet incomplete removal of a ‘disrupted surface layer’ prior to surface pretreatment is shown to have a detrimental effect on the RSW process. The solid wax lubricant used to assist metal forming leads to unpredictable changes in contact resistance, and consequently affects the process stability. For AA6111 closures the final surface topography can influence the RSW process. Standard ‘mill’ and electro-discharge textured (EDT) finish sheet surfaces were examined and preliminary results suggest that both are suitable for welding. The successful application of RSW of aluminium sheet requires careful consideration of the sheet surface condition. This requires close collaboration between material suppliers and automotive manufacturers.

Item Type:

Journal Article

Subjects:

T Technology > TJ Mechanical engineering and machinery
T Technology > TL Motor vehicles. Aeronautics. Astronautics

Divisions:

Faculty of Science > WMG (Formerly the Warwick Manufacturing Group)
Faculty of Science > Engineering

Library of Congress Subject Headings (LCSH):

Aluminum -- Welding, Electric welding -- Research, Joints (Engineering) -- Research, Surfaces (Technology)

Journal or Publication Title:

Journal of Materials Processing Technology

Publisher:

Elsevier SA

ISSN:

0924-0136

Official Date:

1 June 2010

Dates:

Date	Event
1 June 2010	Published

Volume:

Vol.210

Number:

No.8

Number of Pages:

Page Range:

pp. 1076-1082

Identification Number:

10.1016/j.jmatprotec.2010.02.019

Status:

Peer Reviewed

Publication Status:

Published

Access rights to Published version:

Open Access

Funder:

Advantage West Midlands (AWM), Novelis, Jaguar PLC

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