Fakhri, M., Mahmood, I., Al-Mukhtar, A. (2024). The Electrical and Mechanical Aspects of Aluminum and Copper Resistance Spot Weld Joints. , 42(1), 195-205. doi: 10.30684/etj.2023.143734.1606
Marwah S. Fakhri; Ibtihal A. Mahmood; Ahmed Al-Mukhtar. "The Electrical and Mechanical Aspects of Aluminum and Copper Resistance Spot Weld Joints". , 42, 1, 2024, 195-205. doi: 10.30684/etj.2023.143734.1606
Fakhri, M., Mahmood, I., Al-Mukhtar, A. (2024). 'The Electrical and Mechanical Aspects of Aluminum and Copper Resistance Spot Weld Joints', , 42(1), pp. 195-205. doi: 10.30684/etj.2023.143734.1606
Fakhri, M., Mahmood, I., Al-Mukhtar, A. The Electrical and Mechanical Aspects of Aluminum and Copper Resistance Spot Weld Joints. , 2024; 42(1): 195-205. doi: 10.30684/etj.2023.143734.1606

The Electrical and Mechanical Aspects of Aluminum and Copper Resistance Spot Weld Joints

Engineering and Technology Journal
Article 15, Volume 42, Issue 1, January 2024, Pages 195-205    PDF (1.04 M)
Document Type: Research Paper
DOI: 10.30684/etj.2023.143734.1606
Authors
Marwah S. Fakhri* 1; Ibtihal A. Mahmood2; Ahmed Al-Mukhtar3
1Ministry of Higher Education and Scientific Research-Baghdad, Iraq, Mechanical Engineering Dept., University of Technology-Iraq, Alsina’a street, 10066 Baghdad, Iraq.
2Mechanical Engineering Dept., University of Technology-Iraq, Alsina’a street, 10066 Baghdad, Iraq.
3Institute of Structural Mechanics, Bauhaus-Universität Weimar, Germany
Abstract
Resistance spot welding (RSW) is widely used in the automotive industry, particularly for copper-aluminum alloys in electric cars. RSW joint conductivity is crucial for electric vehicles. Welded parts may fracture due to tension, altering conductivity. The study examines resistance spot post-weld joint metallurgy and deformation-induced conductivity changes. The electric resistance of similar and dissimilar RSW joints was examined during tensile tests. Metallurgical tests for RSW joints revealed an increase in grain size from the base metal (BM) to the heat-affected zone (HAZ) and finally the fusion zone (FZ). Satisfactory shear tension strength results were obtained for dissimilar joints (Al-Cu) at 690 N and similar joints (Al-Al) at 780 N, exceeding the minimum limit of 643 N. However, weld strength in similar joints (Cu-Cu) only achieved 933 N, less than the required strength of 1528 N. Furthermore, the relationship between deformation rate (i.e., applied stress) and electrical resistance has been shown. It was found that resistivity increases with increasing deformation stress, resulting in decreased electrical conductivity with a high percentage, representing 99.8, 99.66, and 99.49% for Al-Cu, Al-Al, and Cu-Cu RSW joints, respectively. The electrical resistance was measured at the maximum force of 650 N and maximum stress of 33.1 MPa. The results show (15.7 Ώ, 5.9 Ώ, and 1.99 Ώ) and the electrical conductivities (0.063 IS, 0.169 IS, and 0.502 IS) for the joints (Al-Cu), (Al-Al), and (Cu-Cu), respectively.

Highlights
  • Copper and Aluminum 1050, with 1 mm thickness, were joined by RSW.
  • Metallurgical properties for RSW joints change in three areas: BM, HAZ, and FZ.
  • Electric resistance during tensile tests was investigated for similar and dissimilar RSW joints.
  • Resistivity increases as the deformation increases.
  • The deformation reducing electrical conductivity.
Keywords
Aluminum; Copper; Deformation; Electrical conductivity; Spot welding; Tensile test; HAZ
References
  1. M. Al-Mukhtar, Review of Resistance Spot Welding Sheets: Processes and Failure Mode, Adv. Eng. Forum, 17 (2016) 31–57. http://dx.doi.org/10.4028/www.scientific.net/AEF.17.31
  2. M. Al-Mukhtar, Spot Welding Efficiency and Its Effect on Structural Strength of Gas Generator and Its Performance, Baghdad University, 2002.
  3. S. Fakhri, A. Al-Mukhtar, and I. A. Mahmood, Comparative Study of the Mechanical Properties of Spot Welded Joints, 1079 (2022) 21–28. https://doi.org/10.4028/p-488xsr
  4. Khethier Abbass and H. Hady Abd, A Comparison Study of Mechanical Properties between Friction Stir Welding and TIG Welded Joints of Aluminum Alloy (Al 6061-T6), ET J., 31 (2013) 2701–2715. https://doi.org/10.30684/etj.31.14A.9
  5. Z. Mahdi, S. A. Amin, and S. H. Bakhy, Effect of Different Friction Stir Spot Welding Techniques on the Mechanical Properties and Microstructure of Aluminum AA2024-T3, Al-Nahrain J. Eng. Sci., 22 (2019) 117–123. http://doi.org/10.29194/NJES.22020117
  6. M. Al-Mukhtar, Spot Weldabaility Principles and Considerations. Südwestdeutscher Verlag Für Hochschulschriften Ag Co. Kg, 2015.
  7. M. Al-Mukhtar, Spot Metal Weldability, J. Sci. Eng. Appl., 1 (2018) 45-55.
  8. M. Daws, A.-K. A. Al-Douri, and A. M. Al-Mukhtar, Investigation of Some Welding Parameters in Resistance Spot Welding of Austenitic Stainleass Steel, Coll. Eng. J. Baghdad Univ. Iraq, 2003.
  9. Z. Mahdi, S. A. Amin, and S. H. Bakhy, Influence of Refill Friction Stir Spot Welding Technique on the Mechanical Properties and Microstructure of Aluminum AA5052 and AA6061-T3, IOP Conf. Ser. Mater. Sci. Eng., 671 (2020) 012156. https://doi.org/10.1088/1757-899X/671/1/012156
  10. Khaleel, I. Mahmood, and F. Khoshnaw, Optimization Process of Double Spots Welding of High Strength Steel Using in the Automotive Industry, Eng. Technol. J., 41 (2022) 110–120. https://doi.org/10.30684/etj.2022.134325.1236
  11. Sabah Barrak and S. Khammass Hussein, Optimization the Resistance Spot Welding Parameters of Austenitic Stainless Steel and Aluminum Alloy Using Design of Experiment Method, Eng TechJournal, 34 (2016) 1383–1401. https://doi.org/10.30684/etj.34.7A.11
  12. M. Al-Mukhtar, Case Studies of Aircraft Fuselage Cracking, Adv. Eng. Forum, 33 (2019) 11–18. http://dx.doi.org/10.4028/www.scientific.net/AEF.33.11
  13. M. Al-Mukhtar, Aircraft Fuselage Cracking and Simulation, Procedia Struct. Integr., 28 (2020) 124–131. https://doi.org/10.1016/j.prostr.2020.10.016
  14. M. Al-Mukhtar, T. Rahman, and Q. M. Doos, Spot Welding Joint’s Fracture Behavior and Fundamental,” in Fracture, Fatigue and Wear, Springer, ( 2019)18–27. https://doi.org/10.1007/978-981-13-0411-8_2
  15. M. Al-Mukhtar, Investigation of the Thickness Effect on the Fatigue Strength Calculation, J. Fail. Anal. Prev., 13 (2013) 63–71. https://doi.org/10.1007/s11668-012-9629-2
  16. M. Al-Mukhtar, Fracture mechanics method of welded components under cyclic loads: Fatigue life calculations and simulation. Südwestdeutscher Verlag für Hochschulschriften, 2011.
  17. Zare and M. Pouranvari, Metallurgical joining of aluminium and copper using resistance spot welding: microstructure and mechanical properties, Sci. Technol. Weld. Join., 26 (2021) 461–469. https://doi.org/10.1080/13621718.2021.1935154
  18. Weman, Welding processes handbook. Elsevier, 2011.
  19. Zhang and J. Senkara, Resistance welding: fundamentals and applications. CRC press, 2011.
  20. Napieralska-Juszczak, K. Komeza, F. Morganti, J. K. Sykulski, G. Vega, and Y. Zeroukhi, Measurement of contact resistance for copper and aluminium conductors, Int. J. Appl. Electromagn. Mech., 53 (2017) 617–629. http://dx.doi.org/10.3233/JAE-160025
  21. M. Al-Mukhtar and Q. Doos, The Spot Weldability of Carbon Steel Sheet, Adv. Mater. Sci. Eng., 2013 (2013)1–6. https://doi.org/10.1155/2013/146896
  22. Besson, I. Cousin, A. Dorigny, M. Dabas, and D. King, The temperature correction for the electrical resistivity measurements in undisturbed soil samples: Analysis of the existing conversion models and proposal of a new model, Soil Sci., 173 (2008) 707–720. http://dx.doi.org/10.1097/SS.0b013e318189397f
  23. Kummerow and S. Raab, Temperature Dependence of Electrical Resistivity - Part I: Experimental Investigations of Hydrothermal Fluids, Energy Procedia, 76 (2015) 240–246. https://doi.org/10.1016/j.egypro.2015.07.854
  24. J. den Uijl and R. D. T. Corus, Thermal and Electrical Resistance in Resistance Spot Welding, 17th Int. Conf. Comput. Technol. Weld. Manuf., (2008). http://dx.doi.org/10.13140/RG.2.1.3058.5204
  25. C. Saha, S. Han, K. G. Chin, I. Choi, and Y. D. Park, Weldability evaluation and microstructure analysis of resistance-spot- welded high-Mn steel in automotive application, Steel Res. Int., 83 (2012) 352–357. https://doi.org/10.1002/srin.201100324
  26. S. Wei and T. H. Wu, Electrical contact resistance effect on resistance spot welding, Int. J. Heat Mass Transf., 55 (2012) 3316–3324. http://dx.doi.org/10.1016/j.ijheatmasstransfer.2012.01.040
  27. Afshari, Mechanical Properties of Resistance Spot Welds in Lightweight Applications, (2013)1–18.
  28. Wang, D. Chen, Y. Ran, Y. Yan, H. Peng, and X. Jiang, Fracture characteristics and analysis in dissimilar Cu-Al alloy joints formed via electromagnetic pulse welding, Materials, 12 (2019). https://doi.org/10.3390/ma12203368
  29. Tsakiris, W. Kappel, and G. Alecu, Solid state diffusion welding of Cu-Fe/Al/Ag and Al-Ni dissimilar metals, J. Optoelectron. Adv. Mater., 13 (2011) 1176-1180. http://dx.doi.org/10.13140/2.1.1684.4167
  30. H. Sar, M. H. Ridha, I. M. Husain, and S. K. Hussein, Influence of Welding Parameters of Resistance Spot Welding On Joining Aluminum with Copper, 27 (2022) 217–225. http://dx.doi.org/10.2478/ijame-2022-0029
  31. M. Daws, M. H. Al-saadi, and I. K. A. Al-naimi, Investigation Parameters of Resistance Spot Welding For AA1050 Aluminum Alloy Sheets, J. Eng., 18 (2012) 1128–1141. https://doi.org/10.31026/j.eng.2012.10.04
  32. R. Davis, Copper and copper alloys. ASM international, 2001.
  33. Salimi Beni, M. Atapour, M. R. Salmani, and R. Ashiri, Resistance spot welding metallurgy of thin sheets of zinc-coated interstitial-free steel, Metall. Mater. Trans. A, 50 (2019) 2218–2234. https://doi.org/10.1007/s11661-019-05146-8
  34. Zare and M. Pouranvari, Metallurgical joining of aluminium and copper using resistance spot welding: microstructure and mechanical properties, Sci. Technol. Weld. Join., 26 (2021) 461–469. https://doi.org/10.1080/13621718.2021.1935154
  35. Gabriel, International Standard International Standard, 61010-1© Iec2001, 6 (2003) 13.
  36. Tumuluru, Resistance spot welding techniques for advanced high-strength steels (AHSS). Elsevier Ltd, (2015) 55-70. https://doi.org/10.1016/B978-0-85709-436-0.00004-7
  37. B. Heaney, Electrical conductivity and resistivity, Electr. Meas. Signal Process. Disp., no. October, 14 (2003) 1-7. https://doi.org/10.1201/9780203009406
  38. J. den Uijl and R. D. T. Corus, Thermal and Electrical Resistance in Resistance Spot Welding, 17th Int. Conf. Comput. Technol. Weld. Manuf., 2008. http://dx.doi.org/10.13140/RG.2.1.3058.5204
  39. American and N. Standard, Recommended practices for Resistance Welding, Am. Weld. Socieety, (2000) 1–8.
  40. A. M. Al-Mukhtar and Q. M. Q. Doos, Cracking Phenomenon in Spot Welded Joints of Austenitic Stainless Steel, Mater. Sci. Appl., 4 (2013) 656–662. http://dx.doi.org/10.4236/msa.2013.410081
  41. M. Almukhtar, Fracture simulation of welded joints. Nova Science Publishers Hauppauge, NY, USA, 2011.
  42. Michael and C. C. Koch, Selection of Engineering Materials, (2010)109.
  43. K. Al Naimi, M. H. Al Saadi, K. M. Daws, and N. Bay, Influence of surface pretreatment in resistance spot welding of aluminum AA1050, Prod. Manuf. Res., 3 (2015) 185–200. https://doi.org/10.1080/21693277.2015.1030795
  44. Husain, I. M., Saad, M. L., Barrak, O. S., Hussain, S. K., & Hamzah, M. M., Shear force analysis of Resistance Spot Welding of Similar and Dissimilar Material: copper and carbon steel, 1105 (2021). https://doi.org/10.1088/1757-899X/1105/1/012055
  45. Watmon, T. B., Wandera, C., & Apora, J., Characteristics of resistance spot welding using annular recess electrodes, J. Adv. Join. Process., 2 (2020) 100035 https://doi.org/10.1016/j.jajp.2020.100035
  46. American Welding Society. Resistance Welding Committee and E. A. Fenton, Recommended Practices for Resistance Welding. American Welding Society, 1966.
  47. E. Adesakin, Effect of Linear Deformation on Electrical Conductivity of Metal, 53 (2016) 10–17.
Statistics
Article View: 482
PDF Download: 344


Journal Management System. Powered by iJournalPro.com