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Weldability and Degradation Study of Coated Electrodes for Resistance Spot Welding

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Weldability and Degradation Study of Coated Electrodes for Resistance Spot Welding Weldability and Degradation Study of Coated Electrodes for Resistance Spot Welding By Kevin Randall Chan A thesis presented to the University of Waterloo in fulfillment of the thesis requirement for the degree of Master of Applied Science in Mechanical Engineering Waterloo, Ontario, Canada © Kevin Randall Chan, 2005 I hereby declare that I am the sole author of this thesis. I authorize the University of Waterloo to lend this thesis to other institutions or individuals for the purpose of scholarly research. Kevin R. Chan I further authorize the University of Waterloo to reproduce the thesis by photocopying or other means, in total or in part, at the request of other institutions or individuals for the purpose of scholarly research. Kevin R. Chan ii The University of Waterloo requires the signatures of all persons using or photocopying this thesis. Please sign below, and give address and date. iii Abstract In resistance spot welding of hot dipped galvanized steel sheet, the effect of a TiC metal matrix composite coated electrode on weldability, electrode life and degradation processes was studied. A review of the resistance spot welding process is given, followed by a literature study of the known issues when welding zinc coated steels and some of the methods explored to address those issues. Coated and uncoated Class II CuCrZr domed-flat ‘B’ nose electrodes were used to conduct welding trials. To study the weldability of the coated electrodes compared to the uncoated electrodes, both types were subjected to increasing weld current and time while monitoring resultant weld size. Overall, the coated electrodes showed an improved weldability over the uncoated electrode. Testing revealed that the coated electrode was able to form welds at lower weld current and lower weld time than the uncoated electrode. The range of acceptable weld current and weld time was also increased when using the coated electrode. All other welding parameters were held constant for both electrode types. The cause of the improvement stemmed from the TiC composite electrode coating changing both the electrical and thermal circuit of the welding system. The higher electrical and thermal resistance of the coating material caused the coating to act primarily as a thermal barrier to insulate the heat generated at the faying surface from escaping too quickly through the electrodes. Electrode life testing has shown the TiC composite coating capable of double the tip life of uncoated electrodes. Electrode degradation mechanisms were observed and it was found that the coated electrode was able to delay the zinc-copper interaction, hence the rate of tip wear and length reduction thereby reducing the rate of tip face diameter growth. Cu deposition on the sheet steel was reduced in the early stages of tip life by use of the coated electrodes. With the coating in place, the interaction between the zinc and the copper was hindered and material transfer was prevented even after alloys formed beneath the TiC coating. Study of the degradation mechanisms of the coated electrode revealed that electrode tip growth was due to more than the typical alloying and material loss as well as gross electrode deformation. A unique process involving microscopic deformation and plastic iv flow of alloy layers formed underneath the electrode coating was found to contribute to tip growth while contributing little to electrode length reduction. This process also worked to embed the fragments of electrode coating into the softer underlying alloy layer. Eventual damage to the electrode coating and penetration of zinc caused the loss of the TiC coating, and degradation of the electrode then proceeded as for an uncoated electrode. v Acknowledgments I wish to thank my academic supervisors, Dr. Y. Norman Zhou, Dr. Scott Lawson, and Dr. Yuquan Ding for their time, guidance, support and assistance in this endeavor. Their knowledge and wisdom have guided and encouraged me through the exploration of this research into the realm of welding as well as my own character. Nigel Scotchmer, and the other members at Huys Ind. also deserve thanks and appreciation for their assistance and input to this project. I hope that this work will be able to assist Huys with their future ventures and developments. Financial contributions to this research project included direct funding from Huys Ind., and the Auto 21 Research Initiative. Consumable welding material supplies for research were also provided generously from Huys Ind. as well as Dofasco, without which, this work would not have been possible. My family and friends, and the advanced materials joining group at the University of Waterloo who quickly became my friends have all helped and supported me during this work. I truly appreciate all that they have done in questioning, answering, assisting and enjoying this journey with me. vi Table of Contents Chapter 1............................................................................................................................. 1 Introduction......................................................................................................................... 1 1.1 Resistance Spot Welding .................................................................................... 1 1.2 Steel Coatings..................................................................................................... 3 1.3 Thesis Outline ........................................................................................................... 3 Chapter 2............................................................................................................................. 5 Literature Review................................................................................................................ 5 2.1 Welding Galvanized Steels....................................................................................... 5 2.1.1 Nugget Formation .............................................................................................. 5 2.1.2 Weldability......................................................................................................... 9 2.2 Welding Parameters................................................................................................ 11 2.2.1 Weld current..................................................................................................... 12 2.2.2 Weld Time ....................................................................................................... 12 2.2.3 Weld Force....................................................................................................... 12 2.3 Welding Electrodes................................................................................................. 13 2.4 Electrode Degradation ............................................................................................ 14 2.4.1 Alloy Formation............................................................................................... 15 2.4.2 Wear Mechanisms............................................................................................ 17 2.5 Tip Life Improvement Methods.............................................................................. 21 2.5.1 Improved Steel Coatings.................................................................................. 21 2.5.2 New Electrode Geometry................................................................................. 23 2.5.3 Spin Electrodes ................................................................................................ 25 2.5.4 New Electrode Materials.................................................................................. 28 2.5.5 Compound Electrodes...................................................................................... 30 2.5.6 Electrode Coating............................................................................................. 35 2.6 Summary................................................................................................................. 37 Chapter 3........................................................................................................................... 39 Experimental Methods...................................................................................................... 39 3.1 Material................................................................................................................... 39 3.2 Electrodes................................................................................................................ 41 3.2.1 Uncoated Electrodes ........................................................................................ 41 3.2.2 Coated Electrodes ............................................................................................ 41 3.3 Welding Trial Procedures ....................................................................................... 43 3.3.1 Weldability Study ............................................................................................ 43 3.3.2 Electrode Life Trials ........................................................................................ 44 3.4 Welding Trial Parameters ....................................................................................... 45 3.4.1 Weldability Study ............................................................................................ 45 3.4.2 Electrode Life Trials ........................................................................................ 46 3.5 Static Resistance ....................................................................................................
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