PSI- Issue 9

Mohammad Jameel Zedan et al. / Procedia Structural Integrity 9 (2018) 37–46 Mohammad Jameel Zedan, et al./ Structural Integrity Procedia 00 (2018) 000–000

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Fig. 5. Pullout failure mode of RSW joint.

3.3. Welding nugget diameter Figure 6 shows the cross-section of the weld nugget. The upper side is steel, and the lower is aluminum. The relationships between the three factors and the welding nugget diameter have been presented in Figs. 7, 8. The nugget diameter decreases when the electrode force increases from 1500 N to 2100 N. Then, the nugget diameter increases when the electrode force increases to 2400 N. The welding nugget diameter is increased by increasing the welding current at the electrode force 1500 and 2400 N. When the electrode force is 2100, the welding nugget diameter is reduced by increasing the welding current from 11.25 to 12.75 KA. Then, it’s increased by increasing the welding current to 14.25 KA. The welding nugget diameter is increased by increasing welding time from 25 to 40 cycles at different current and electrode force.

Fig. 6. Cross-sectioned of the weld nugget.

Fig. 7. The relationship between the welding time and the nugget diameter, electrodes force 2400 N.