Forum for Science, Industry and Business

Sponsored by:     3M 
Search our Site:

 

Robots find regular teeth brushing helps them munch through 50,000 aluminium spot welds

12.09.2006
New automated polishing process produces 50,000 high quality resistance spot aluminium welds on just one set of electrodes.

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
Further information:
http://www.warwick.ac.uk
http://www2.warwick.ac.uk/newsandevents/pressreleases/NE1000000221701/

More articles from Automotive Engineering:

nachricht The car of the future – sleeper cars and travelling offices too?
18.06.2018 | Fraunhofer-Institut für Arbeitswirtschaft und Organisation IAO

nachricht Self-driving cars for country roads
07.05.2018 | Massachusetts Institute of Technology, CSAIL

All articles from Automotive Engineering >>>

The most recent press releases about innovation >>>

Die letzten 5 Focus-News des innovations-reports im Überblick:

Im Focus: UNH scientists help provide first-ever views of elusive energy explosion

Researchers at the University of New Hampshire have captured a difficult-to-view singular event involving "magnetic reconnection"--the process by which sparse particles and energy around Earth collide producing a quick but mighty explosion--in the Earth's magnetotail, the magnetic environment that trails behind the planet.

Magnetic reconnection has remained a bit of a mystery to scientists. They know it exists and have documented the effects that the energy explosions can...

Im Focus: A Chip with Blood Vessels

Biochips have been developed at TU Wien (Vienna), on which tissue can be produced and examined. This allows supplying the tissue with different substances in a very controlled way.

Cultivating human cells in the Petri dish is not a big challenge today. Producing artificial tissue, however, permeated by fine blood vessels, is a much more...

Im Focus: A Leap Into Quantum Technology

Faster and secure data communication: This is the goal of a new joint project involving physicists from the University of Würzburg. The German Federal Ministry of Education and Research funds the project with 14.8 million euro.

In our digital world data security and secure communication are becoming more and more important. Quantum communication is a promising approach to achieve...

Im Focus: Research icebreaker Polarstern begins the Antarctic season

What does it look like below the ice shelf of the calved massive iceberg A68?

On Saturday, 10 November 2018, the research icebreaker Polarstern will leave its homeport of Bremerhaven, bound for Cape Town, South Africa.

Im Focus: Penn engineers develop ultrathin, ultralight 'nanocardboard'

When choosing materials to make something, trade-offs need to be made between a host of properties, such as thickness, stiffness and weight. Depending on the application in question, finding just the right balance is the difference between success and failure

Now, a team of Penn Engineers has demonstrated a new material they call "nanocardboard," an ultrathin equivalent of corrugated paper cardboard. A square...

All Focus news of the innovation-report >>>

Anzeige

Anzeige

VideoLinks
Industry & Economy
Event News

Optical Coherence Tomography: German-Japanese Research Alliance hosted Medical Imaging Conference

19.11.2018 | Event News

“3rd Conference on Laser Polishing – LaP 2018” Attracts International Experts and Users

09.11.2018 | Event News

On the brain’s ability to find the right direction

06.11.2018 | Event News

 
Latest News

New materials: Growing polymer pelts

19.11.2018 | Materials Sciences

Earthquake researchers finalists for supercomputing prize

19.11.2018 | Information Technology

Controlling organ growth with light

19.11.2018 | Life Sciences

VideoLinks
Science & Research
Overview of more VideoLinks >>>