ProgramMaster Logo
Conference Tools for 2023 AWS Professional Program
Login
Register as a New User
Help
Submit An Abstract
Propose A Symposium
Presenter/Author Tools
Organizer/Editor Tools
About this Abstract
Meeting 2023 AWS Professional Program
Symposium 2023 AWS Professional Program
Presentation Title Mapping of a Resistance Spot Weld Properties onto a Space Defined by Base Material Attributes
Author(s) Olga Eliseeva, Jerry Gould, Emma Brunst
On-Site Speaker (Planned) Olga Eliseeva
Abstract Scope Introduction: Spot welding is integral to automotive construction. A typical automobile body-in-white design may consist of 10s to 100s of spot-welded metal stack-ups, including a range of sheet metal types, gauges, and material combinations. Modern techniques for characterizing vehicle performance (stiffness, NVH, crash) requires that each one of these stack-ups be characterized for mechanical performance. Historically, joint performance characteristics for each stack-up have been assessed experimentally. Such testing however is extremely time-consuming and cannot keep up with the rapid changes occurring in both the characteristics of the sheet materials as well as intended stack-ups in the design. As automotive manufacturers push for reduced time to market, development of the necessary stack-up specific performance data becomes more difficult. Recently, the application of design of experiment (DOE) methods have been used as a tool decrease the testing required to obtain critical data. However, traditional DOE approaches still address only the stack-ups included design, and cannot be extrapolated. To address this challenge, a new novel approach to extrapolate data from such designs of experiments to future stack-ups. This work has investigated a method of collecting data based on specific stack-ups, and mapping those results onto a new design space where material strength and gauge for the component materials can be assessed independently. This then creates tools that allow prediction of stack-up performance not included in the original experiment and entire reference databases to be created. Experimental: In this study a design of experiment was created including stack-ups with a diversity of material strengths and thicknesses. This range was selected to build the data-bases necessary for mapping onto the expanded material characteristics space. The created DOE included 2 testing configurations (tensile and peel), 2 weld sizes (4√t and 5√t) and 12 separate stack-ups. Cross tension and tensile shear testing were employed here consistent with existing automotive performance databases. The resulting design of experiment was a specialty design, consisting of 24 trials. Samples were then prepared and testing conducted in accordance with the DOE. Regression modeling and extrapolation of the results provided performance attribute data for all 12 stack-ups for the two test configurations and weld sizes. This included 48 individual performance attributes. These results were then used as the input for a second regression curve fit. For this second curve fit, a general linear model was created that used as input variables component material strength and gauge, relative weld size, and the test configuration as its input variable. For this analysis steels ranged in thickness from .65mm to 1.6mm, and strengths from 270MPa to 1180Mpa. Analysis using this new general linear model created a map that allowed prediction of cross tension and tensile shear loads based on the strengths and thicknesses of the two attached steels along with the relative weld size. Results and Discussion: Initial curve fitting of these results provided a regression equation showed that the measured joint strengths correlated with the input variables with an R2 value of 89%. Significant factors include the specific stack-up, stack-up2 test configuration, weld size, and one two factor interaction, test configuration*weld size. This model was then used to create a new database for analysis, where each stack-up was decomposed into the component sheet thicknesses and strengths. This resulted in a 48-trial matrix. Regressing this new dataset against the expanded list of variables resulted in a correlation of 98% R2. The resulting model included independent terms for each of the main effects except one material strength. In addition, interactions between material strengths and gauges, as well as weld size and test configuration were noted. This then created the model that offered potential for predicting the performance of stack-ups with a wide range of material strengths and thicknesses. Conclusions: This technique of generating data for a defined set of stack-ups onto a space where the substrates are separated is a powerful first order tool for understanding the impact of newer materials and configurations on vehicle design. This analysis methodology further offers potential for continuous database expansion based on adding newer grades and a wider range of gauges. Further, this tool in combination with artificial intelligence strategies offers potential for quickly acquiring and analyzing data facilitating rapid manufacturing.
Proceedings Inclusion? Undecided

OTHER PAPERS PLANNED FOR THIS SYMPOSIUM

A Brief History of Welding Metallurgy in IIW
A Fundamental Investigation into Intermetallic Formation and Growth in the Aluminum-Iron System using Resistance-based Diffusion Couples
A New CALPHAD-based Finite Element Tool for Additive Manufacturing Simulation
Accelerating Ni-Cr Filler Metal Design with a Coupled CALPHAD and Data Analytics Approach
Additive Manufacturing and Welding of Ni-base Superalloys for Concentrated Solar Power Systems
Additive Manufacturing of Steel-aluminum Bimetallic Structures
Alloy Design and Additive Manufacturing of Functionally Graded Materials for Olefin Furnaces
Alloy Development via Multi-wire Arc Additive Manufacturing (m-WAAM)
Application of NDE Techniques for Safer Pressure Vessels
Applications of Emerging Artificial Intelligence Tools in Additive Manufacturing
Arc and Droplet Transfer Behavior During Electrode-negative Polarity Cold Metal Transfer and Electrode-positive Pulse Gas Metal Arc Deposition of Ti-6Al-4V Alloy
Arc Length Behaviour and Voltage Predictions for GMAW-Sp Aluminum Procedures in the Lincoln Procedure Handbook
Automated Vision-based Laser Weld and Braze Quality Systems
Bond Formation Mechanism of High-frequency Electric Resistance Welding Of X65 Grade Pipeline Steel by Physical Simulation
Capacitor Discharge Based Resistance Welding of Aluminum Alloy and Galvanized Steel Sheets
Carbide Precipitation during Temper Bead Welding in the HAZ of Low Alloy Steels
Challenges in Wire-Arc Additive Manufacture of Nickel Aluminum Bronze
Characterization of Vibration Welded Wood
Charpy Reconstitution Joining Procedure: Supporting Reactor Pressure Vessel Operation Beyond 60 Years
Comparison of Constant Load and Slow Strain Rate Tensile Tests for Evaluation of Hydrogen Assisted Cracking Susceptibility in Dissimilar Metal Weld
Comparison of Crystallographic Texture Before and After Post-weld Heat Treatment of Electric Resistance Welded X65 Linepipe
Computational Design of Experiment Process-microstructure-property Optimization in Welding and Additive Manufacturing
Computational Process-Microstructure-Property Optimization for Fe-10Ni Groove Welds
Connecting X-ray Computed Tomography to Fatigue Life of Ti-6Al-4V using Quantitative Fractography
Construction of a Unified Fatigue S-N Curve Incorporating the Effects of Residual Stress Level in Welded Joints
Correlation Between the Coarse and Fine Grain Haz Hardness of Pipeline Girth Welds
Creep Performance of Austenitic Stainless Steels Processed with Wire Arc Directed Energy Deposition
Critical Evaluation of NDE Methods and Their Effectiveness for Defect Detection in Laser Powder Bed Fusion Components
Crystallographic Texture and Microstructure of Dissimilar Steel Welds for Filler Metal Selection
Database of Hydrogen Assisted Cracking Susceptibility in Dissimilar Metal Welds
Deep Learning Based Real-time and In-situ Monitoring of Weld Penetration: Where We are and What are Needed Revolutionary Solutions?
Defect Formation Mitigation during Laser Welding of Aluminum Alloys using Beam Oscillation
Deleterious Effects of Laser Welding Nitinol without Argon Shielding Gas
Development of a Fast Analysis Solver for Welding Sequence Optimization of Ship Structures
Development of a New Technique to Assess Spot Welding Cracking of Gen3 High Strength Steel Sheets
Dissimilar Brazing of Ti-6Al-4V to Stainless Steel Under Thermal Conditions used for Glass Sealing
Do We Need a New Foundation to Use Deep Learning to Monitor Weld Penetration?
Droplet Temperature Measurements in GMAW
Effect of Additive Manufacturing Process Parameters on the Microstructure and Mechanical Properties of AF9628 Steel
Effect of Base Metal Dilution on Microstructure and Thermal Stability in Anviloy Wire-H13 Clads
Effect of Martensite-Austenite Morphology on Charpy Toughness of Cold-wire Tandem Submerged-arc Welded X70 Steel
Effect of Preheating Temperatures on Microstructure of L-DED Grade 91
Effect of Retained δ-ferrite on the Nucleation of Laves Phase during Artificial Aging in Grade P92 Steel Welds
Effect of the Notching Method on Charpy V-notch Impact Energy Outcomes
Effect of Wire Preheat and Feed Rate in X80 Steel Laser Welds
Effects of Deposition Sequence on Microstructural Evolution in Additively Manufactured Cu-Cr-Nb Alloy / Superalloy Bimetallic Structures
Energy Distribution and Effects on Weld and Defect Formation during Beam Oscillation Laser Welding of a Nickel Alloy
Erection Stage Longi Welding Robot System in Shipbuilding
Estimation of Bead Size and Catchment Efficiency in Laser Cladding
Evaluation of Inoculated High Strength Aluminum Wire 6061 for GMA DED
Feasibility of LP-DED and L-PBF Processes in the Repair of GTD 111 Turbine Blades using René 65 Powder
Fluidity of Aluminum Welding Wires
Friction Stir Welding of Rolled Homogenous Armor (RHA) and High Hardness Armor (HHA) Steels
From Frustrating to Flawless: Mastering Class A Aluminum Resistance Welding
General Linear Models in Additive Manufacturing: Interpretability and Prediction of Aggregated Ti-6Al-4V Fatigue Data
General Thermomechanical Model of FSW Based on a Characteristic Temperature for Deformation and Heat Transfer
Geometrical Feature Development for Multi-Process DED of Aerospace Structures using Ultra High Strength Steel (UHSS)
High Ductility Brazes of Nickel-superalloys Using a Multi Principal Element Alloy Filler
Hot Wire Semi-auto Gas Tungsten Arc Welding (GTAW) for Shipbuilding Applications
Identifying Deposit Profile for Gas Metal Arc Directed Energy Deposition
Industrialization Challenges in Welding and Large Scale Metal Fabrication
Influence of Alloy Composition and Nitride Formation on Delta Phase Precipitation in Additively Manufactured Inconel® 625
Influence of Hydrogen Shielding Gas Additions on Base Metal Dilution, Bead Shape and Wall Buildability in Fe-10Ni Gas Metal Arc DED
Influence of Welding Parameters on Weld Reinforcement in Tandem Submerged Arc Welding
Inoculated High Strength High Strength Aluminum Wire Feedstocks for Welding and DED
Integrating a Novel Approach to Advanced Materials during Resistance Spot Welding for the Automotive Industry
Investigation of Defects Process Map in Friction Stir Welding
Investigation of Fe-10 wt.% Ni Steel Weld Metal Hydrogen Induced Cracking Susceptibility using the Gapped Bead on Plate (GBOP) Test
Investigation of Intermetallic Phase Formation during RSW of Advanced Automotive Steels and Aluminum Alloys
Isothermal Low Cycle Fatigue of Steel to Ni-based Alloys Dissimilar Joints
Laser Beam Directed Energy Deposition (L-DED) of an Fe-Si-B-Nb-Cu Soft Magnetic Alloy
Laser Beam Welding of Wrought and Additively Manufactured Ti-5Al-5V-5Mo-3Cr Alloys
Laser Welding of Al-Cu Interconnects for E-Mobility Applications: Effect of Beam Oscillation on Metal Mixing, Microstructure, and Mechanical Property
Linear Solid State Welding w/ NO Fusion Line. Fine Grained Base to Base Using 95% Less Energy
Machine Learning for GMAW Weld Quality
Machine Learning for Predicting Weld Quality and Properties in Resistance Spot Welding Process
Mapping of a Resistance Spot Weld Properties onto a Space Defined by Base Material Attributes
Mechanizing Self Shielded Flux Core Wire to Achieve Robust Toughness on Girth Welds in Pipeline Construction
Metallurgical Characterization of Rotary Inertia Friction Welded Dissimilar 422 Martensitic Stainless Steel to 4140 Low Alloy Steel Piston Joints
Methodology Development of Ultra-high Temperature Mechanical Performance of Additively Manufactured Refractory Alloys
Microstructural Heterogeneities in Electron Beam Additively Manufactured Haynes 282
Monitoring Torch Position and Weld Quality with Reversed Electrode Image during GTAW Process
Monitoring Weld Penetration using a Deep Learning Model Pre-trained from Filtered Current
My 40 Years as a Welding Engineer in the Oil and Gas Industry
Next Generation Double Electrode GMAW Processes for Precision Fillet Welding
Nickel Aluminum Bronze Weld Metal Microstructures in Wire Arc Additive Manufacturing with Cryogenic Cooling
Nondestructive Characterization of Grade 92 Steel Weld Microstructures using, Micro-resolution Ultrasonic Imaging System.
Numerical Modeling of Arc Plasma and Shielding Gas Flows in Wire Arc Additive Manufacturing of Tall Walls
Numerical Modeling of Resistance Spot Welding Processes and Liquid Metal Embrittlement Cracking
Numerical Modelling of Temperature and Velocity of WC-Co-Cr Particles in the HVOF Process using DJ2700 Gun and Hydrogen as a Fuel
Online Quality Monitoring Method in Gas Metal Arc Welding Based on Vision Camera and Laser Vision Sensor
Open-source Numerical Modeling of Solidification Cracking Susceptibility: Application to Refractory Alloy Systems
Optimization and Characterization of FSpJ for Al Alloys and Polymeric Materials: Experimental and Numerical Investigations
OSU Faculty Overview-Metallurgy and Weldability
OSU Faculty Overview-Processes
OSU Faculty Overview - Design, Modeling and Nondestructive Evaluation
Overview of Arc Welding Activities at IIW and Standardization of Laser Welding/Cutting
Overview of RW Projects for the Automotive Industry
Plenary Talk: Delta Ferrite and Rapidly Solidified Microstructure in Welding and Additive Manufacturing of Martensitic Steels
Practical Calculation of Cooling Rate, HAZ Width, and Thermal Features in Welding and Additive Manufacturing
Precipitation Kinetics in Additively Manufactured Alloy K-500 and Commission IV Activities
Predicting Laser Weld Variability in 304 Stainless Steel Resulting from Composition Variation
Process Advantages of Laser Hybrid Welding of Thick-walled Steel Structures of Wind Tower
Process Control of a Custom Designed Adaptive Weld Head
Reduction of Cold Cracking in Welded Overlays via Reduced Martensite Start Temperature
Robotic Path Planning for Wire Arc Additive Applications of Aerospace Aluminum Alloys
Robotizing Double-electrode GMAW by Learning from Human Welders
Scanning for Metrology in Wire-Arc Additive Manufacturing
Shoring Up Long Lead Time Supply Chain Issues of Forgings and Castings using Advanced Manufacturing
SiC and Nickel-base Superalloy Dissimilar Joining using Multi-principal Element Alloy Fillers
Silicate-free Tandem GMAW for Shipbuilding Applications
Solidification Behavior and Microstructure Evolution in Dissimilar Electron Beam Welds between Commercially Pure Iron and Nickel
Solidification Behavior of Laser-wire Directed Energy Deposition Austenitic Stainless Steel
Stress Relaxation Cracking Susceptibility in 347H SS Welds and Their Repairs
The Ohio State University Welding Engineering Program - the First 75 Years
The Role of Diffusion Brazing Technology for the Repair of Gas Turbine Engine Components
The Role of Material Selection and Thermal Cycling on Tool Life in Refill Friction Stir Spot Welding
Thermal Faceting on the Ductility-Dip Cracking Fracture Surfaces of Nickel-Based Alloys – Occurrence, Characterization, and Implications for the Cracking Mechanism
Thermo-Mechanical Fatigue of Welding Defect-containing Boiler Water Walls
Thermodynamic and Kinetic Calculation of Stainless-steel Solidification – revisiting the WRC-1992 Diagram
Ultrasonic Assisted Soldering of Metallized Polymer Current Collectors for Li-Ion Batteries
Ultrasonic Welding of Dissimilar Materials
Ultrasonically Assisted Resistance Spot Welding of Multilayer Foils in Battery Manufacturing
WE in the Power Generation Industry
Weld Vac – A Quiet, Clean Metal Removal System
Welding Engineering in the Aircraft Engine Industry
Welding in Space: Past, Present, and Future
Wobble Laser Beam Welding in Keyhole Mode

Questions about ProgramMaster? Contact programming@programmaster.org