Adaptive welding indentation control (AWIC)

Purpose and goal

The purpose of the project was to evaluate if and how the electrode displacement during the RSW-process can be used as a quality measurement of the welds. The objectives of the pre-study were reached. The results from the project shows that the continuous electrode displacement correlates to the both the quality of the weld (the spot weld has reached required size) as well as the risk for spattering. The electrode displacement could therefore be used as a quality assurance method. An aim for the project was also to discuss a possible continuation project, which has been done.

Expected results and effects

Since the pre-study demonstrates a relationship between the electrode displacement and the growth of the weld it enables the possibility to use the electrode displacement as a method to measure the quality of each weld. Commercial equipment that can perform these kinds of measurements is also available and makes the method more interesting for the industry. Before implementation further development work is needed. Long term effects after continuation project is to reduce the number of welds.

Planned approach and implementation

The pre-study contained a short literature study of earlier work within the field. This was followed by a measuring system and an experimental part that contained two separate electrode displacement measurements methods that was tested on sheet combinations with varying degree of complexity. The displacement curves were compared with the weld quality and analyzed with both cross-section analysis and peel tests. Results and possible ways forward have been discussed as a base line for a future project.