Development of a methodology for simulation-based analysis of resistance spot welding processes with motion overlay on the example of aluminum materials

• Applicants: Professor Dr.-Ing. Uwe Füssel; Professor Dr.-Ing. Steffen Ihlenfeldt
• Subject Area: Joining and Separation Technology
• Term: since 2015
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 266896522

Resistance spot welding is a highly productive and reliable process for joining metallic workpieces by means of simple equipment. In addition to the joining of steels, the trend toward lightweight construction is increasingly leading to the joining of light metals, such as aluminum, using resistance spot welding. In this process, a frictional, frictionless or oscillating relative movement superimposed on the infeed of the electrodes can significantly increase productivity, weld quality and electrode life. The reason for this is the destruction of electrically insulating surface layers (aluminum oxide) associated with the relative movement. The research project is the first to systematically characterize the physical and materials-related processes occurring in the contact between the electrode and the sheet during the superimposition of motion and, on the basis of experimental results, to qualitatively record and finally mathematically model the mechanisms of action that lead to the destruction of the oxide layer and to electrode wear. From this, scientifically based approaches for increasing tool life and process reliability in resistance spot welding of aluminum alloys are presented.

• DFG Programme: Research Grants