On-line inspection of weld quality based on dynamic resistance curve in resistance spot welding and weldbonding

摘要

In order to reduce destructive testing of car sub-assemblies, on-line inspection of weld quality has gained more and more concern in terms of both resistance spot welding (RSW) and weldbonding. Dynamic resistance directly determines the amount of heat generated by current flow and consequently reflects nugget formation and growth, which is one of the most effective technologies for quality inspection. Under the measurements of voltage and current at the secondary circuit of a welding transformer, this paper proposes a method for on-line inspection of weld quality based on two indicators from dynamic resistance curve: time to nugget initiation and durable time to nugget expansion. Firstly, during the welding process of RSW and weldbonding, the proper range of time to nugget initiation and durable time to nugget expansion for good welds is set up. Then on-line inspection of weld quality on the basis of the developed proper range of these two indicators is carried out. The experimental results show the following conclusions: it is clearly able to separate accepted welds without expulsion from the welds of unaccepted nugget size in both RSW and weldbonding; the proper range for good welds, independent of electrode wear, is obtained only for a new electrode.