Short-Pulse Welding Technique for Resistance Spot Welding of Aluminum Alloy 6016-T4

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dc.contributorBarkey, Mark
dc.contributorJordon, J. Brian
dc.contributorZürn, Michael
dc.contributor.advisorBalasubramanian, Bharat
dc.contributor.advisorBrewer, Luke N.
dc.contributor.authorSchulz, Eric
dc.contributor.otherUniversity of Alabama Tuscaloosa
dc.date.accessioned2022-04-13T20:34:02Z
dc.date.available2027-09-01
dc.date.issued2020
dc.descriptionElectronic Thesis or Dissertationen_US
dc.description.abstractThe objective of this research is to develop and characterize the use of the short-pulse welding approach for the resistance spot welding (RSW) process on aluminum alloy 6016-T4. Aluminum alloys are increasingly used in automobile body-in-white production concepts to address weight and fuel efficiency requirements. RSW remains a preferred method of joining due to speed, existing equipment, maintenance experience, low cost, and absence of an added joining element. The purpose of the short-pulse welding technique is to improve the consistency of weld quality and to reduce undesired defects including rapid degradation of the welding electrodes, poor surface appearance of the joint, and expulsion of molten material from the welding zone. Additionally, the technique provides significant energy and process time savings to enable a more efficient and flexible application in production. In this work, RSW process simulations and experimental welding tests using two medium frequency direct current (MFDC) welding systems were used to develop the approach. The effects of RSW process parameters on the size of the fusion zone were studied, and it was found that short welding times could be used with the same current and force levels to produce the same welding result. In addition, the use of sharp, rectangular shaped pulses led to more effective nugget development due to more efficient heating of the fusion zone. Further analysis evaluated the electrode wear process for short-pulse RSW of this alloy and the benefits obtained by reduction of pulse width. Finally, combined RSW simulations and experiments examined the solidification and development of fusion zone microstructure using the short-pulse welding approach.en_US
dc.format.mediumelectronic
dc.format.mimetypeapplication/pdf
dc.identifier.otherhttp://purl.lib.ua.edu/182085
dc.identifier.otheru0015_0000001_0004238
dc.identifier.otherSchulz_alatus_0004D_14258
dc.identifier.urihttps://ir.ua.edu/handle/123456789/8417
dc.languageEnglish
dc.language.isoen_US
dc.publisherUniversity of Alabama Libraries
dc.relation.hasversionborn digital
dc.relation.ispartofThe University of Alabama Electronic Theses and Dissertations
dc.relation.ispartofThe University of Alabama Libraries Digital Collections
dc.rightsAll rights reserved by the author unless otherwise indicated.en_US
dc.subjectAluminum alloys
dc.subjectAutomotive Joining
dc.subjectResistance spot welding
dc.subjectWelding technology
dc.titleShort-Pulse Welding Technique for Resistance Spot Welding of Aluminum Alloy 6016-T4en_US
dc.typethesis
dc.typetext
etdms.degree.departmentUniversity of Alabama. Department of Mechanical Engineering
etdms.degree.disciplineMechanical Engineering
etdms.degree.grantorThe University of Alabama
etdms.degree.leveldoctoral
etdms.degree.namePh.D.

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