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Numerical and experimental analysis of heat transfer in resistance spot welding process of aluminum alloy AA5182

Piott, Michael and Werber, Alexandra and Schleuß, Leander and Ossenbrink, Ralf and Doynov, Nikolay and Michailov, Vesselin G. (2020) Numerical and experimental analysis of heat transfer in resistance spot welding process of aluminum alloy AA5182. International Journal of Advanced Manufacturing Technology (111), pp. 1671-1682. Springer Nature. doi: 10.1007/s00170-020-06197-7. ISSN 0268-3768.

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In this work, a numerical model and experiments are used to investigate heat transfer processes during resistance spot welding process of aluminum. For this purpose, calibrated heat transfer conditions and thermal contact conductance are transferred from a previous work to a coupled thermal-electrical-mechanical finite element model. First, all domains of the numerical model are validated by an experimental study. The experimental setup includes the measurement of current, voltage drops, electrode force, electrode displacement, and temperatures while two sheets of aluminum alloy AA5182 are joined. Computational results show that most of the generated Joule heat (78%) is stored in the electrodes or transferred to cooling water until the end of weld time. Heat transfer by natural convection and thermal radiation is very small and can in general be neglected for complete process. Afterwards, the influence of electrode water-cooling on welding process is investigated numerically. The results indicate that the generation of Joule heat and thermal energy of the sheets during weld time is only slightly affected by electrode water-cooling. As a consequence, water-cooling conditions do not affect nugget formation. In contrast, electrode water-cooling highly influences cooling conditions during hold time.

Item URL in elib:https://elib.dlr.de/139738/
Document Type:Article
Title:Numerical and experimental analysis of heat transfer in resistance spot welding process of aluminum alloy AA5182
AuthorsInstitution or Email of AuthorsAuthor's ORCID iD
Piott, MichaelMercedes-Benz-AG, SindelfingenUNSPECIFIED
Werber, AlexandraMercedes-Benz-AG, SindelfingenUNSPECIFIED
Ossenbrink, RalfBTU CottbusUNSPECIFIED
Doynov, NikolayBTU CottbusUNSPECIFIED
Michailov, Vesselin G.BTU CottbusUNSPECIFIED
Date:15 October 2020
Journal or Publication Title:International Journal of Advanced Manufacturing Technology
Refereed publication:Yes
Open Access:No
Gold Open Access:No
In ISI Web of Science:Yes
Page Range:pp. 1671-1682
Publisher:Springer Nature
Series Name:Springer Nature
Keywords:Aluminum resistance spot welding , Heat transfer, FE simulation, Electrode water-cooling, Instrumented experiments
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 11:06
Last Modified:19 Feb 2021 13:25

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