نوع مقاله : مقاله پژوهشی
عنوان مقاله English
نویسندگان English
The shunting effect is one of the critical challenges in consecutive resistance spot welding (RSW) of aluminum alloys, as it alters the current distribution and reduces the heat generation at subsequent welding locations. Accurate prediction of this phenomenon is essential for controlling weld quality and improving process reliability. In this study, a thermo-electrical analytical model is developed to predict the shunting effect during consecutive resistance spot welding of AA2219 aluminum alloy sheets. The proposed model is based on an electrical-thermal energy balance approach and incorporates temperature-dependent electrical resistivity, thermal conductivity, and specific heat capacity of the material. The influence of previous weld nuggets on the current path and heat generation during subsequent welding operations is considered through an equivalent shunting resistance formulation. The developed model is experimentally validated using resistance spot welding tests performed under controlled welding conditions. The predicted weld nugget dimensions and thermal behavior show good agreement with experimental measurements, demonstrating the capability of the proposed approach in describing the effect of shunting on weld formation. The results indicate that the reduction in effective welding current and heat input caused by shunting can significantly influence nugget growth, particularly in consecutive welding sequences. The developed model provides a computationally efficient tool for analyzing and optimizing resistance spot welding parameters in aluminum alloy assemblies.
کلیدواژهها English