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A study of the heat transfer mechanism in resistance spot welding of aluminum alloys AA5182 and AA6014

Piott, Michael and Werber, Alexandra and Schleuss, Leander and Doynov, Nikolay and Ossenbrink, Ralf and Michailov, Vesselin G. (2020) A study of the heat transfer mechanism in resistance spot welding of aluminum alloys AA5182 and AA6014. International Journal of Advanced Manufacturing Technology (111), pp. 263-271. Springer Nature. doi: 10.1007/s00170-020-05650-x. ISSN 0268-3768.

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Abstract

This work investigates heat transfer mechanism of aluminum resistance spot welding process. The main target is to determine thermal contact conductance and heat transfer coefficients for natural convection and thermal radiation at ambient air and forced convection inside the water-cooled electrodes. For this purpose, the heat transfer of hot sheets in a welding gun for aluminum alloys AA5182 and AA6014 is analyzed experimentally and numerically. The transient temperature field is measured by several thermocouples in a simplified experimental setup. Subsequent thermal-mechanical coupled finite element simulations of the experiments were used to calibrate the heat transfer coefficients. The heat transfer coefficient for natural convection and thermal radiation to ambient air is 13 W m2 K and the heat transfer coefficient for forced convection of electrode water-cooling is 25,000 W m2 K. The results indicate that the thermal contact conductance can be assumed ideal for welding process. Additionally, the finite element model is validated by the measured and calculated dissipated heat due to forced convection. Finally, a sensitivity analysis is performed to compare the influence of maximum and minimum heat transfer coefficients of forced convection (water-cooling) on transient temperature field and dissipated heat of sample AA5182.

Item URL in elib:https://elib.dlr.de/139542/
Document Type:Article
Title:A study of the heat transfer mechanism in resistance spot welding of aluminum alloys AA5182 and AA6014
Authors:
AuthorsInstitution or Email of AuthorsAuthor's ORCID iD
Piott, MichaelMercedes-Benz AG, Sindelfingen, GermanyUNSPECIFIED
Werber, AlexandraMercedes-Benz AG, Sindelfingen, GermanyUNSPECIFIED
Schleuss, LeanderLeander.Schleuss (at) dlr.deUNSPECIFIED
Doynov, NikolayDepartment of Joining and Welding Technology, Brandenburg University of Technology (BTU) Cottbus-SenftenbergUNSPECIFIED
Ossenbrink, RalfDepartment of Joining and Welding Technology, Brandenburg University of Technology (BTU) Cottbus-SenftenbergUNSPECIFIED
Michailov, Vesselin G.Department of Joining and Welding Technology, Brandenburg University of Technology (BTU) Cottbus-SenftenbergUNSPECIFIED
Date:25 September 2020
Journal or Publication Title:International Journal of Advanced Manufacturing Technology
Refereed publication:Yes
Open Access:No
Gold Open Access:No
In SCOPUS:Yes
In ISI Web of Science:Yes
DOI :10.1007/s00170-020-05650-x
Page Range:pp. 263-271
Publisher:Springer Nature
Series Name:Springer Nature
ISSN:0268-3768
Status:Published
Keywords:Aluminum resistance spot welding, Heat transfer, FE simulation, Thermal contact conductance Electrode water-cooling
HGF - Research field:Energy
HGF - Program:Energy Efficiency, Materials and Resources
HGF - Program Themes:Other
DLR - Research area:Energy
DLR - Program:E SP - Energy Storage
DLR - Research theme (Project):E - Low-Carbon Industrial Processes (old)
Location: Cottbus
Institutes and Institutions:Institute of Low-Carbon Industrial Processes
Deposited By: Klinkmüller, Maike
Deposited On:04 Jan 2021 10:50
Last Modified:19 Feb 2021 13:24

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