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

  • 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 validatedThis 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.show moreshow less

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Metadaten
Author: Michael Piott, Alexandra Werber, Leander Schleuss, Nikolay DoynovORCiD, Ralf OssenbrinkORCiD, Vesselin MichailovORCiDGND
DOI:https://doi.org/10.1007/s00170-020-05650-x
ISSN:0268-3768
ISSN:1433-3015
Title of the source (English):International Journal of Advanced Manufacturing Technology
Document Type:Scientific journal article peer-reviewed
Language:English
Year of publication:2020
Tag:Aluminum resistance spot welding; Electrode water-cooling; FE simulation; Heat transfer; Thermal contact conductance
Volume/Year:Vol. 111
First Page:263
Last Page:271
Faculty/Chair:Fakultät 3 Maschinenbau, Elektro- und Energiesysteme / FG Füge- und Schweißtechnik
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