Resistance spot welding research by Paul Briskham at the University of Warwick's Warwick Manufacturing Group in conjunction with Douglas Boomer of Innoval Technology and engineers from Jaguar and Land Rover has achieved a landmark result of 50,000 high quality welds on automotive-grade aluminium sheet using just one set of standard copper electrodes on an automated robotic welding system.
The remarkably long electrode life was achieved by polishing the copper electrodes during the brief gap in time between each welded component.
Resistance spot welding is the most widely used process for joining steel sheet in the automotive industry, largely because it is the most cost-effective method for high-volume production and excellent at pulling together components prior to welding. However, a major hurdle preventing the adoption of this joining process for aluminium automotive sheet has been the problem of short electrode life and associated loss of weld quality.
Previous studies have shown that the electrode life can be extended to a few thousand welds by regular tip dressing using a form-cutter, of the type commonly deployed to maintain the electrodes when welding galvanized or high-strength steels. This study has demonstrated the significant additional improvement in electrode life that can be gained by using a system that polishes the electrodes with an abrasive wheel to maintain their domed profile.
This resistance spot welding study has also investigated low-cost methods for detecting electrode damage to determine automatically when to conduct electrode maintenance and when to change the electrodes, which could lengthen the electrode life even further.
Peter Dunn | alfa
The car of the future – sleeper cars and travelling offices too?
18.06.2018 | Fraunhofer-Institut für Arbeitswirtschaft und Organisation IAO
Self-driving cars for country roads
07.05.2018 | Massachusetts Institute of Technology, CSAIL
For the first time ever, scientists have determined the cosmic origin of highest-energy neutrinos. A research group led by IceCube scientist Elisa Resconi, spokesperson of the Collaborative Research Center SFB1258 at the Technical University of Munich (TUM), provides an important piece of evidence that the particles detected by the IceCube neutrino telescope at the South Pole originate from a galaxy four billion light-years away from Earth.
To rule out other origins with certainty, the team led by neutrino physicist Elisa Resconi from the Technical University of Munich and multi-wavelength...
For the first time a team of researchers have discovered two different phases of magnetic skyrmions in a single material. Physicists of the Technical Universities of Munich and Dresden and the University of Cologne can now better study and understand the properties of these magnetic structures, which are important for both basic research and applications.
Whirlpools are an everyday experience in a bath tub: When the water is drained a circular vortex is formed. Typically, such whirls are rather stable. Similar...
Physicists working with Roland Wester at the University of Innsbruck have investigated if and how chemical reactions can be influenced by targeted vibrational excitation of the reactants. They were able to demonstrate that excitation with a laser beam does not affect the efficiency of a chemical exchange reaction and that the excited molecular group acts only as a spectator in the reaction.
A frequently used reaction in organic chemistry is nucleophilic substitution. It plays, for example, an important role in in the synthesis of new chemical...
Optical spectroscopy allows investigating the energy structure and dynamic properties of complex quantum systems. Researchers from the University of Würzburg present two new approaches of coherent two-dimensional spectroscopy.
"Put an excitation into the system and observe how it evolves." According to physicist Professor Tobias Brixner, this is the credo of optical spectroscopy....
Ultra-short, high-intensity X-ray flashes open the door to the foundations of chemical reactions. Free-electron lasers generate these kinds of pulses, but there is a catch: the pulses vary in duration and energy. An international research team has now presented a solution: Using a ring of 16 detectors and a circularly polarized laser beam, they can determine both factors with attosecond accuracy.
Free-electron lasers (FELs) generate extremely short and intense X-ray flashes. Researchers can use these flashes to resolve structures with diameters on the...
13.07.2018 | Event News
12.07.2018 | Event News
03.07.2018 | Event News
16.07.2018 | Physics and Astronomy
16.07.2018 | Life Sciences
16.07.2018 | Earth Sciences