Real-Time Ultrasonic Evaluation of the Aluminum Resistance ......Real-Time Ultrasonic Evaluation of the Aluminum Resistance Spot Welding Process W. Perez Regalado, A. Chertov, R. Gr.
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Real-Time Ultrasonic Evaluation of the Aluminum
Resistance Spot Welding ProcessW. Perez Regalado, A. Chertov, R. Gr. Maev
“Real-Time Ultrasonic Evaluation
of the Aluminum Resistance
Spot Welding Process”
Waldo J. Perez Regalado
Dr. Roman Gr. Maev
Dr. Andrey Chertov
Institute for Diagnostic Imaging Research
University of Windsor
Real-Time Ultrasonic Evaluation of the Aluminum
Resistance Spot Welding ProcessW. Perez Regalado, A. Chertov, R. Gr. Maev
Contents:
2
•Spot Welding Process
•Destructive Testing
•Offline NDT
•Inline NDT
•Real-Time Weld Analyzer
•Aluminum Inline RSW Monitoring
•Conclusions
Real-Time Ultrasonic Evaluation of the Aluminum
Resistance Spot Welding ProcessW. Perez Regalado, A. Chertov, R. Gr. Maev
Spot Welding Process
3
[1] www.nsrw.com
Real-Time Ultrasonic Evaluation of the Aluminum
Resistance Spot Welding ProcessW. Perez Regalado, A. Chertov, R. Gr. Maev
Spot Welding Process
4
Spot welding is
highly
automated
today
Regular
vehicle
contains
3000-4000
spot welds
Real-Time Ultrasonic Evaluation of the Aluminum
Resistance Spot Welding ProcessW. Perez Regalado, A. Chertov, R. Gr. Maev
Destructive Testing
55
5
Peel test Cross-section
Cons: Selective testing;
Time consuming;
Labour intensive.
More than 99% of the parts are never
checked. For this reason, at the design
stage, additional spot welds are introduced
into the assembly process.
Real-Time Ultrasonic Evaluation of the Aluminum
Resistance Spot Welding ProcessW. Perez Regalado, A. Chertov, R. Gr. Maev
Offline NDT
6
The part to be inspected should be pulled
out from the production line and scanned
manually
Real-Time Ultrasonic Evaluation of the Aluminum
Resistance Spot Welding ProcessW. Perez Regalado, A. Chertov, R. Gr. Maev
Inline NDT
7
Pulser/RecieverWelding
Machine
PC
Real-Time Ultrasonic Evaluation of the Aluminum
Resistance Spot Welding ProcessW. Perez Regalado, A. Chertov, R. Gr. Maev
Inline NDT
8
0 50 100 150 200 250-0.2
-0.15
-0.1
-0.05
0
0.05
0.1
0.15Pressure Signal p(t)
Time x 1/60 Seconds
Am
plit
ude
0 20 40 60 80 100 120 140 160-0.2
-0.15
-0.1
-0.05
0
0.05
0.1
0.15Pressure Signal p(t)
Time x 1/60 Seconds
Am
plit
ude
Real-Time Ultrasonic Evaluation of the Aluminum
Resistance Spot Welding ProcessW. Perez Regalado, A. Chertov, R. Gr. Maev
Inline NDT
99
PC
1
2
3
4
5
Incident wave
Copper Electrode
Steel Plate 1
Steel Plate 2
Copper Electrode
Molten
Nugget
Current ON
Arr
iva
l T
ime 1
2
34
5
Welding time
Ultrasonic probe
built into
electrode*
** Ultrasonic In-Process Monitoring And Feedback Of Resistance Spot Weld Quality.
Patent application by R.Gr. Maev and A.M. Chertov. Attorney Docket No. 706940US1
**
Arrival time
Am
plit
ud
e 1
2 34
5
Real-Time Ultrasonic Evaluation of the Aluminum
Resistance Spot Welding ProcessW. Perez Regalado, A. Chertov, R. Gr. Maev
Real-Time Integrated Weld Analyzer
10
Metals:
•Mild steel
•High strength steel
•Dual phase steel
Coatings:
•Bare
•Galvanneal
•Galvanized
www.tessonics.com
Real-Time Ultrasonic Evaluation of the Aluminum
Resistance Spot Welding ProcessW. Perez Regalado, A. Chertov, R. Gr. Maev
Real-Time Integrated Weld Analyzer
11
d1
d2
d3
d1
d2
d3
d1
d2
d3
d1
d2
d3
d1
d2
d3
d1
d2
d3
d1
d2
d3
Real Acoustic Image Pattern Weld geometry
Real-Time Ultrasonic Evaluation of the Aluminum
Resistance Spot Welding ProcessW. Perez Regalado, A. Chertov, R. Gr. Maev
Real-Time Integrated Weld Analyzer
12
Stick Weld (0.0 mm) Good Weld (5.4 mm)
Steel Plate 1 Steel Plate 1
Steel Plate 2 Steel Plate 2
Time, ms
0 150 300 450 600 0 150 300 450 600
Welding current
Time, ms
Welding current
Real-Time Ultrasonic Evaluation of the Aluminum
Resistance Spot Welding ProcessW. Perez Regalado, A. Chertov, R. Gr. Maev
Real-Time Integrated Weld Analyzer
13
Welding Time x 2 ms
Tim
e O
f F
ligh
t x
15
ns
50 100 150 200 250
50
100
150
200
250
Nugget Penetration
Estimate nugget
diameter with
Maximum TOF
Real-Time Ultrasonic Evaluation of the Aluminum
Resistance Spot Welding ProcessW. Perez Regalado, A. Chertov, R. Gr. Maev
Aluminum RSW Monitoring
14
Steel B-Scan
Welding Time x 2 ms
Tim
e O
f F
light
x 1
5 n
s
50 100 150 200 250
50
100
150
200
250
Welding Time x 2 ms
Tim
e O
f F
light
x 1
5 n
s
50 100 150 200 250
50
100
150
200
250
Aluminum B-Scan
Real-Time Ultrasonic Evaluation of the Aluminum
Resistance Spot Welding ProcessW. Perez Regalado, A. Chertov, R. Gr. Maev
Aluminum RSW Monitoring
15
Q= I2RtAluminum Steel
Weld Time 60 ms 200 ms
Current 21 kA 9 kA
Table 2 - Welding Schedules for 1 mm plates
Steel B-Scan
Welding Time x 2 ms
Tim
e O
f F
light
x 1
5 n
s
50 100 150 200 250
50
100
150
200
250
Welding Time x 2 ms
Tim
e O
f F
light
x 1
5 n
s
50 100 150 200 250
50
100
150
200
250
Aluminum B-Scan
Real-Time Ultrasonic Evaluation of the Aluminum
Resistance Spot Welding ProcessW. Perez Regalado, A. Chertov, R. Gr. Maev
Aluminum RSW Monitoring
16
LPT Interface
DSP based
Electromechanical multiplexer (1 ms switch time )
66 MHz 10 bit ADC
B-Scan storage of 28 KB
USB2.0 interface
FPGA based
Electronic multiplexer (8 us switch time)
133 MHz 12 bit ADC
B-Scan storage of 2 MB
Welding Time x 2 ms
Tim
e O
f F
light
x 1
5 n
s
50 100 150 200 250
50
100
150
200
250
Welding Time x 0.6 ms
Tim
e O
f F
light
x 7
.5 n
s
50 100 150 200 250 300
50
100
150
200
250
300
Real-Time Ultrasonic Evaluation of the Aluminum
Resistance Spot Welding ProcessW. Perez Regalado, A. Chertov, R. Gr. Maev
Aluminum RSW Monitoring
17
Welding Time x 0.7 ms
Tim
e O
f F
light
x 7
.5 n
s
50 100 150 200 250
50
100
150
200
250
Welding Time x 0.7 ms
Tim
e O
f F
light
x 7
.5 n
s
50 100 150 200 250
50
100
150
200
250
Welding Time x 0.7 ms
Tim
e O
f F
light
x 7
.5 n
s
50 100 150 200 250
50
100
150
200
250
After 10 welds After 50 welds After 100 welds
Real-Time Ultrasonic Evaluation of the Aluminum
Resistance Spot Welding ProcessW. Perez Regalado, A. Chertov, R. Gr. Maev
Aluminum RSW Monitoring
18
Thickness varies depending on the storing of the material but goes
from 5 nm - 2 µm
Property Value
Density 3.95-4.1 g/cm3
Melting Point 2072 °C
Electrical Resistivity 1x1014 Ω·cm
Thermal Conductivity 5.43 W/m/K
Thermal Expansion 10–6/°C
Aluminum
Aluminum
Oxide
Real-Time Ultrasonic Evaluation of the Aluminum
Resistance Spot Welding ProcessW. Perez Regalado, A. Chertov, R. Gr. Maev
Aluminum RSW Monitoring
19
[2] Muhammad Rashid “Some Influences of Tribology in Resistance Spot
Welding of Aluminum Alloys” Ph.D Thesis University of Waterloo
A) Metal - Metal
B) Metal – Oxide
C) Air Gap
D) Oxide - Oxide
Real-Time Ultrasonic Evaluation of the Aluminum
Resistance Spot Welding ProcessW. Perez Regalado, A. Chertov, R. Gr. Maev
Aluminum RSW Monitoring
20
Electrode Pitting and Alloying
[3] I. Lum, S. Fukumoto, E. Biro, D.R. Boomer, and Y. Zhou, “Electrode Pitting in Resistance Spot
Welding of Aluminum” 2004 Metallurgical and Materials transaction A (35A). pp. 217–225.
A) CuAl2B) C) AlCu
D) CuAl2E) Cu9Al4
Real-Time Ultrasonic Evaluation of the Aluminum
Resistance Spot Welding ProcessW. Perez Regalado, A. Chertov, R. Gr. Maev
Aluminum RSW Monitoring
21
[4] S.J. Dong and Y. Zhou “Effects of TiC Composite Coating on Electrode
Degradation” Metallurgical and Materials Transactions A 2007
Real-Time Ultrasonic Evaluation of the Aluminum
Resistance Spot Welding ProcessW. Perez Regalado, A. Chertov, R. Gr. Maev
Aluminum RSW Monitoring
22
0
1
2
3
4
5
6
0 100 200 300 400 500 600 700 800
Nu
gg
et
Dia
me
ter
( m
m)
Weld Number
Cap Degradation
A
C
Real-Time Ultrasonic Evaluation of the Aluminum
Resistance Spot Welding ProcessW. Perez Regalado, A. Chertov, R. Gr. Maev
Aluminum RSW Monitoring
23
Cap Degradation
The Peltier Effect
A
C
Real-Time Ultrasonic Evaluation of the Aluminum
Resistance Spot Welding ProcessW. Perez Regalado, A. Chertov, R. Gr. Maev
Aluminum RSW Monitoring
24
Transducer Installation
Welding Time x 0.8 ms
Tim
e O
f F
light
x 1
5 n
s
50 100 150 200 250 300
50
100
150
200
250
300
After 0 WeldsWelding Time x 0.8 ms
Tim
e O
f F
light
x 1
5 n
s
50 100 150 200 250 300
50
100
150
200
250
300
After 100 WeldsWelding Time x 0.8 ms
Tim
e O
f F
light
x 1
5 n
s
50 100 150 200 250 300
50
100
150
200
250
300
After 200 Welds
Welding Time x 0.8 ms
Tim
e O
f F
light
x 1
5 n
s
50 100 150 200 250 300
50
100
150
200
250
300
After 300 WeldsWelding Time x 0.8 ms
Tim
e O
f F
light
x 1
5 n
s
50 100 150 200 250 300
50
100
150
200
250
300
After 400 WeldsWelding Time x 0.8 ms
Tim
e O
f F
light
x 1
5 n
s
50 100 150 200 250 300
50
100
150
200
250
300
After 500 Welds
Industry Average:
Cap dressing every 100 welds
Real-Time Ultrasonic Evaluation of the Aluminum
Resistance Spot Welding ProcessW. Perez Regalado, A. Chertov, R. Gr. Maev
Aluminum RSW Monitoring
25
Welding Time x 1 ms
Tim
e O
f Flig
ht x 7
.5 n
s
50 100 150 200 250 300 350
50
100
150
200
250
300
1 mm
Plate 1 ( 0.9 mm )
Plate 2 ( 1.9 mm )
Welding Time x 1 ms
Tim
e O
f Flig
ht x 7
.5 n
s
50 100 150 200 250 300 350
50
100
150
200
250
300
1 mm
Real-Time Ultrasonic Evaluation of the Aluminum
Resistance Spot Welding ProcessW. Perez Regalado, A. Chertov, R. Gr. Maev
Aluminum RSW Monitoring
26
c t
RF
RB
Nugget Diameter Estimation
R² = 0,8044
0
1
2
3
4
5
6
7
90 95 100 105 110 115 120
Nu
gg
et
Dia
me
ter
( m
m )
H ( uS )
Real-Time Ultrasonic Evaluation of the Aluminum
Resistance Spot Welding ProcessW. Perez Regalado, A. Chertov, R. Gr. Maev
Conclusions
27
• Inline ultrasonic monitoring of the aluminum spot welding process is possible, however
faster acquisition hardware is required.
• The aluminum oxide formed on the substrate surface, causes rapid electrode deterioration.
The Peltier effect increases the deterioration on the anode electrode, therefore the
ultrasonic probe should be installed on the cathode side.
• Time of flight is not a good indicator of nugget size on aluminum. A new metric that takes
into consideration the time when the maximum temperature was achieved was proposed
showing good correlation with nugget diameter.
• Liquid penetration can be measured from the ultrasonic B-Scans.
Real-Time Ultrasonic Evaluation of the Aluminum
Resistance Spot Welding ProcessW. Perez Regalado, A. Chertov, R. Gr. Maev
QUESTIONS ???
More details:
perezr@uwindsor.ca
http://www.idirresearch.com/
http://www.tessonics.com/
28
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