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Resistance Spot Welding of Steel Sheets of the Same and Different Thickness

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DOI: 10.11118/actaun201765030807

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ACTA UNIVERSITATIS AGRICULTURAE ET SILVICULTURAE MENDELIANAE BRUNENSIS

Volume 65 83 Number 3, 2017

https://doi.org/10.11118/actaun201765030807

RESISTANCE SPOT WELDING OF STEEL SHEETS

OF THE SAME AND DIFFERENT THICKNESS

Milan Brožek1, Alexandra Nováková1, Ota Niedermeier2

Department of Material Science and Manufacturing Technology, Faculty of Engineering, Czech University of Life
1

Sciences Prague, Kamýcká 129, 165 21 Praha 6 – Suchdol, Czech Republic

AŽD Praha, spol. s r. o., Žirovnická 2, 106 00 Praha 10 – Záběhlice, Czech Republic
2

Abstract

BROŽEK MILAN, NOVÁKOVÁ ALEXANDRA, NIEDERMEIER OTA. 2017. Resistance Spot Welding
of Steel Sheets of the Same and Different Thickness. A
 cta Universitatis Agriculturae et Silviculturae
Mendelianae Brunensis, 65(3): 807–814.

Resistance welding ranks among progressive and in practice often used manufacturing techniques of
rigid joints. It is applied in single‑part production, short‑run production as well as in mass production.
The basis of this method is in the utilization of the Joulean heat, which arises at the passage of current
through connected sheets at collective influence of compressive force. The aim of the carried out tests
was the determination of the dependence between the rupture force of spot welds made using steel
sheets of the same and different thickness for different welding conditions. For carrying out of this
aim 360 assemblies were prepared. The sheets (a total of 720 pieces) of dimensions 100 × 25 mm and
thickness of 0.8 mm, 1.5 mm and 3.0 mm were made from low carbon steel. In the place determined
for welding the test specimens were garnet blasted and then degreased with acetone. The welding of
two specimens always of the same (0.8+0.8 mm, 1.5+1.5 mm a 3.0+3.0 mm) and different (0.8 + 1.5 mm,
0.8+3.0 mm a 1.5+3.0 mm) thickness was carried out using the welding machine type BV 2,5.21. At this
type the welding current value is constant (Imax = 6.4 kA). The welding time (the time of the passage
of the current) was changed in the whole entirety, namely 0.10 s, 0.15 s, 0.20 s, 0.25 s, 0.3 s, 0.4 s,
0.6 s, 0.8 s, 1.0 s, 1.3 s, 1.6 s and 2.0 s. The compressive force was chosen according to the thickness of
the connected sheets in the range from 0.8 to 2.4 kN. From the results of carried out tests it follows that
using the working variables recommended by the producer we obtain the quality welds. But it we use
the longer welding times, we can obtain stronger welds, namely up to 21 % compared to welds made
using working variables recommended by the producer.

Keywords: Resistance welding; steel sheet; laboratory test; shear testing resistance spot welds

Ruža, 1988) or welding and overlaying (Blaščík et al.,

INTRODUCTION 1987; Brožek, 2012; 2011).
Joints of two or more parts used in practice are A row of welding methods exists today – they
usually divided into removable and rigid ones. are classified according to ČSN EN ISO 4063. One
Removable joints, made e.g. using screws, washers of them is resistance welding (resistance welding,
and nuts, we can repeatedly dismantle and assemble method 2). In the world the resistance welding
without damage of above mentioned parts. On is known already since eighteen eighties. But in
the contrary, rigid joints are permanent. They can our country it begins to be used since nineteen
be “dismantled” (affect of strength or heat), but at thirties. Since then the technology has been very
the cost of their irreversible damage (destruction). advanced. Today spot welding is used not only for
It is a case of joints made by riveting (Brožek and welding of ferrous steels including stainless steels
Nováková, 1995), adhesive bonding of metallic (Liu et al., 2011; 2013; Peasura, 2011; Pouranvari,
and non‑metallic materials (Brockmann et al., 2009; 2011), but also of non‑ferrous metals (Field and
Brožek, 2014b; Brožek, 2013a; Brožek, 2013d), Sutton, 1941; Kramár, 2015). It is possible to weld
soldering (Brožek, 2013b; 2013c; Nippes, 1983; sheets with previous surface finish, e.g. zinc‑coated

807
808 Milan Brožek, Alexandra Nováková, Ota Niedermeier

sheets (Hayat and Sevim, 2012; Svítil, 1980; Wang Q = R.I2.t (1)
et al., 2013). Without problems it is today possible
to weld two different materials, too (Kaščák, 2014; Where
Kolařík, 2012). The most typical application of Q ��� Heat (J),
resistance welding technology is today in car R ���� Resistance (Ω),
industry (Hipperson and Watson, 1950; Hipperson, I ����� Welding current (A)
1952; Hayat and Sevim, 2012). Modern technologies t ����� Welding time (s).
make possible the on‑line quality monitoring and The heat Q, which is needed to the melting‑down
controlling of resistance spot welding (Li, 2012). It of the required metal volume, can be achieved
is paid attention to the spot welds behavior under by two ways. Depending on this we distinguish
conditions of fatigue (Younger et al., 1966). the short time welding conditions (high I, short
According to ČSN EN ISO 4063 the resistance t) and the long time welding conditions (low I,
welding falls into spot welding (resistance spot long t). The final quality of spot welds depends
welding, method 21) and seam welding (resistance on the optimum setting of the working variables
seam welding, method 22). At the spot welding, by the operator, primarily on the welding current
which is studied in this contribution, the weld intensity, on the time of the current passage and on
is created in the contact of welded materials the compressive force.
(sheets) between surfaces of two electrodes.
The area of the weld (so called nugget or button)
is approximately the same as the area of the ends MATERIALS AND METHODS
of the electrodes (Hipperon and Watson, 1950; Size, dimensions and shear testing procedure
Holásek, 1968; Zhang and Senkara, 2012). of spot welds for sheets of thickness from 0.5 mm
At the resistance welding (Welding Committee, to 10.0 mm are stated in the standard ČSN EN
1956; Li, 2012; Brožek, 2014a; 2015; 2016) ISO 14273. The size of test specimens is different
the collective influence of Joulean heat (1), arising depending on the welded sheets thickness.
by passage of current through the welded materials, The width ranges from 45 mm to 100 mm,
and compressive force, is used. exceptionally from 30 mm to 100 mm. The length
ranges from 175 mm to 320 mm. The lapping
length ranges from 35 to 100 mm. Therefore
the dimensions of the specimens were unified. They

1: Dimensions and shape of test specimens

2: Macrostructure of spot weld, sheet thickness 1.5 + 1.5 mm, t = 2.0 s

 Resistance Spot Welding of Steel Sheets of the Same and Different Thickness 809

I: Welding variables
Orientation welding speed,
Sheet thickness, mm Welding time, s Compressive force, kN
spot·h−1
0.8 + 0.8 0.15 0.8 180
1.5 + 1.5 0.6 1.5 56
3.0 + 3.0 1.6 2.4 26
Note: Variables for the sheet thickness 3.0 + 3.0 were recalculated.

were used the dimensions of test specimens used in and remedial workshops and fitting shops.
our department already over a long period for tests The reason is the highest permissible current and
of adhesive bonded joints, soldered joints or riveted heat load of electrodes, which are cooled only by air.
joints. The producer recommends the welder for
The test specimens for spot welding were made welding of steel sheets from low‑carbon steel till to
from the low‑carbon steel 11 321.21 according ČSN Cmax = 0.3 % and 2.5 + 2.5 mm thickness. Owing to
41 1321 (steel DC01 according EN, steel St1203 study reasons the spot welds of sheets 3.0 + 3.0 mm
according DIN). Sheets of size 1000 × 2000 mm were carried out, too.
and thickness 0.8 mm, 1.5 mm and 3.0 mm were The main parts of the spot welder are the welding
the semi‑products for their production. The parting transformer type T 2,5.12, the lever weighting and
of semi‑products to test specimens was carried out the electronic device type QX 12.1. The electronics
by shearing. The dimensions and shape of the test ensures the reproducible setting of the chosen
specimens and the location of the spot weld (nugget) selected variables and the compensation of possible
is evident from Fig. 1 (L = 100 mm, b = 25 mm, changes of the supply voltage. The required
l = 25 mm). Illustration of macrostructure of spot compressive force is set by means of the spring by
weld is shown in Fig. 2. turn of the setting nut. The welding time (time of
The surface preparation of the test specimens the current passage) is possible to set in 12 steps from
before the spot welding is very important. All 0.1 to 2.0 s. According to the producer instruction
potential dirt on the material surface decreases it is possible to make only limited number joints
the joint strength, or makes impossible the spot within a hour, which depends on the welded sheets
weld formation. Therefore the surface of all thickness (Tab. I). At this welder the welding time t
specimens was blasted under the angle 90° using and the compressive force F (Tab. I) are the basic
artificial garnet (fraction MESH 80, abrasive grain parameters, which is possible to set. The welding
size 0.1 to 0.3 mm) on one end (determined for current cannot be changed (Imax = 6.4 kA).
welding) on both sides during 30 mm. After blasting For the purpose of the experiment always
all specimens were degreased using acetone and the couple of specimens (assembly) of the same
dried using warm air. Immediately the spot welding thickness was spot welded, so 0.8 + 0.8 mm,
ensued. 1.5 + 1.5 mm and 3.0 + 3.0 mm and also of
The surface roughness of sheets before and after the different thickness, so 0.8 + 1.5 mm,
blasting was measured (according to ČSN EN ISO 0.8 + 3.0 mm a 1.5 + 3.0 mm. For each sheet
4287) with apparatus for measuring roughness thickness the making of 5 assemblies was proposed,
Surftest SJ‑301. In doing so, there were checked always at the use of all 12 welding times (0.10 s,
two parameters, Ra (arithmetical mean deviation 0.15 s, 0.20 s., 0.25 s, 0.3 s, 0.4 s, 0.6 s, 0.8 s, 1.0 s,
of the assessed profile, μm) and Rz (maximum 1.3 s, 1.6 s, and 2.0 s). 355 usable assemblies were
height of profile, μm). In each of the six series of made, 5 assemblies failed to be welded. It is the case
samples the measurement was repeated ten times in of sheet of 3.0 mm thickness at the shortest welding
the direction of the longer dimension of the sample, time 0.10 s. After welding all assemblies were loaded
and ten times in the direction of the shorter using the universal test machine LabTest 5.50 ST
dimension of the sample. It was performed in total till to their rupture. Speed of loading of the welded
of 240 measurements. A very good repeatability assemblies was 10 mm·min−1. The spot weld rupture
of surface preparation was proved by evaluation; was characterized by the destruction in the spot
determined roughness values between each series weld (nugget) or in the sheet.
of samples differed only minimally. Sheet roughness
(Ra) before adjustment was 0.91 ± 0.14 μm, Rz was
6.6 ± 1.1 μm. Sheet roughness Ra after treatment was
2.56 ± 0.33 μm, Rz was 21.3 ± 3.7 μm.
For welding of the assembly consisting from two
specimens of the same and different thickness
the spot welder type BV 2,5.21 was used. The welder
uses the long time welding conditions. It is
determined only for shops with piece production
and so for the lower work intensity, e.g. for school
810 Milan Brožek, Alexandra Nováková, Ota Niedermeier

3: Destruction in the spot weld (nugget), sheet thickness 3.0 + 3.0 mm, t = 0.6 s

4: Destruction in the sheet, sheet thickness 1.5 + 3.0 mm, t = 0.6 s

 Resistance Spot Welding of Steel Sheets of the Same and Different Thickness 811

RESULTS AND DISCUSSION however, the trend changed and the bearing point of
The results of the carried out tests are shown in the spot weld was practically constant. Explanation
Fig. 5 and Fig. 6. At all measured values the standard of cause is the same as in previous samples. Spot
deviation is demonstrated by the line segments. welds of sheets of thickness 3.0 + 3.0 mm could
In Fig. 5 there are the results obtained on samples not be made at the lowest welding time (t = 0.1 s).
made from sheets of equal thickness. For sheets of With increasing time of passage of current (from
thickness 0.8 + 0.8 mm at increasing welding time t = 0.15 s), the strength of spot welds relatively
there was a slight increase in strength (up to t = 0.4 s). sharply, almost linearly, increased up to the time
With further increasing time of passage of current the current passes t = 0.8 s. In a further lengthening
the strength of the joints practically did not change. the time of welding, the strength increased further,
Explanation of causes can be found in the mode of but less dramatically. The highest strength of
failure of the spot weld. While for shorter periods spot welds were made during the longest time of
of welding there was always the destruction of passage of the current (t = 2.0), which used spot
the spot weld, for longer periods of passage of welder allows. Unlike the two previous groups of
the welding current there is always a breach of samples, in these samples the breach in the weld
the welded material. More significant change of always occurred. The cause is probably the amount
the strength of spot welds occurred in sheets of of heat supplied to the weld. This is especially for
thickness 1.5 + 1.5 mm. When the welding time shorter times insufficient to create a quality spot
was increased there was practically linear increase weld. Possibility of welding these thicknesses is
in resistance of spot connections (to t = 0.8 s). not declared by equipment manufacturer. It can
With further increasing time of passage of current,

5: Relation between rupture force and time of passage of current (sheets of the same thickness),
the standard deviation is demonstrated by the line segments

6: Relation between rupture force and time of passage of current (sheets of different thickness),
the standard deviation is demonstrated by the line segments
812 Milan Brožek, Alexandra Nováková, Ota Niedermeier

be stated that the joints had considerable strength, using the working variables recommended by
especially at longer welding times (over t = 0.8 s). the producer, do not reach the highest rupture
In Fig. 6 there are the results obtained on samples force. The producer of the welder evidently has
made from sheets of different thicknesses. The test taken into consideration, although he has not
results of spot welds sheets of thickness 0.8 + 1.5 mm stated it, the economical production of spot welds.
and 0.8 + 3.0 mm are very similar, almost identical. The welds made using the working variables
For lower welding time (up to t = 0.4 s) the strength recommended by the producer are no doubt quality
of spot welds increased. For longer welding time and in operation reliable. But when a customer
(above t = 0.6 s) the joint strength further, but using this welder will demand the highest joint
only very slightly, increased, and this increase was rupture force, it is necessary to use the working
practically linear. For these two combinations of variables recommended by the authors of
plate thicknesses occurred destruction of joints in the contribution and obtained on the basis of
welded material of less thickness during all welding the carried out experiments. But he has to take into
times. Different results were obtained in spot weld consideration that at the prolonged time of current
sheets of thickness 1.5 + 3.0 mm. Bond strength passage the energy consumption increases and
increased rapidly until the passage of current t = 0.4 the production will cost more than expected. But
s. With the increase in the time of passage of current by the prolonged passage of current it is possible
(up to t = 0.8 s) the strength of spot welds further to increase the spot weld rupture force at sheets
increased, but less dramatically. When longer times of thickness 0.8 + 0.8 mm of about 11 %, at sheets
of welding had been used, the strength of spot welds of thickness 1.5 + 1.5 mm of about 21 %, at sheets
did not increase anymore. Explanation of cause is of thickness 3.0 + 3.0 mm of about 4 %, at sheets of
again to be found in evaluation of destruction of thickness 0.8 + 1.5 mm of about 18 %, at sheets of
spot weld. Likewise the case with connections of thickness 0.8 + 3.0 mm of about 7 % and at sheets
sheets of the same thickness (0.8 mm and 1.5 mm), of thickness 1.5 + 3.0 mm of about 3 % compared to
there are times when shorter welding always caused welds made using the welding variables according
a violation of the spot weld and for longer periods to the producer. By the experiments it was further
of welding there is always a violation of material proved that using the spot welder type BV 2,5.21 it
welded joints. is possible to weld successful thicker sheets than it is
In comparison with data stated in Tab. I, Fig. 5 stated, concretely of thickness 3.0 + 3.0 mm.
and Fig. 6 we find out that the spot welds, made

CONCLUSION
In the contribution the rupture force results of the spot welds tests of the assemblies from two
sheets of the same and different thickness are published. The spot welds were made using the spot
welder BV 2,5.21. The test specimens of size 100 × 25 mm were made from the low‑carbon steel.
In the place of the future weld the sheets were before welding on both sides garnet blasted and
degreased with acetone. In total 355 assemblies were spot welded using different working variables.
Following variables were changed: welded sheets thickness (0.8 + 0.8 mm, 1.5 + 1.5 mm, 3.0 + 3.0 mm,
0.8 + 1.5 mm, 0.8 + 3.0 mm and 1.5 + 3.0 mm) and time of current passage (0.10 s, 0.15 s, 0.20 s, 0.25 s,
0.3 s, 0.4 s, 0.6 s, 0.8 s, 1.0 s, 1.3 s, 1.6 s and 2.0 s); the welding current intensity was constant (Imax = 6.4
kA). The compressive force was chosen according to the welded sheets thickness from 0.8 to 2.4 kN.
On the basis of the carried out tests it is possible to state:
The spot weld rupture was characterized by the destruction in the spot weld (at shorter welding time)
or in the sheet (at longer welding time),
Using the working variables recommended by the producer (Tab. 1) we obtain always quality and in
practice usable welds,
If we use longer welding times we obtain welds of higher rupture force, namely of 3 to 21 % compared
to by the producer recommended variables,
The use of the longer welding time means however higher electric energy consumption and so higher
costs; therefore this welding conditions are applicable only there, where it is explicitly demanded.
 Resistance Spot Welding of Steel Sheets of the Same and Different Thickness 813

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Contact information
Milan Brozek: [email protected]

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