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<p>The paper is aimed at the analysis of the influence of the welding current source (type-AC/DC) and its connection to the electrical grid on the quality of the resistance projection welding process (nuts/bolds). The investigation is based on FEM-SORPAS analysis. The relationship between (i) weld strength, (ii) the area of the melted material in the contact area of the welded elements, i.e., projection—sheet metal, and (iii) the volume of the melted material in the welding area is described in relation to the type of the welding current (AC/DC). Selected FEM calculations were referred to experimental results. In the second step, the influence of a source type and connection method on the decrease of the welding current was determined by a circuit modelling using the FALSTAD simulation environment. The obtained results show that the voltage drop and current decrease caused by the line connections and converter structure significantly reduce the strength of the joint. For nominal parameters, i.e., welding current source (type-AC/DC), the FEM calculation results were verified experimentally. Metallographic examinations of welded joints (AC/DC) were performed and compared with the temperature distribution in the welding area for FEM.</p>

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Comparative analysis of a projection welding process with AC and DC current source for susceptibility study

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2025年8月2日

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  • Zygmunt Mikno,
  • Mariusz Stepien,
  • Yu-Jun Xia

摘要

The paper is aimed at the analysis of the influence of the welding current source (type-AC/DC) and its connection to the electrical grid on the quality of the resistance projection welding process (nuts/bolds). The investigation is based on FEM-SORPAS analysis. The relationship between (i) weld strength, (ii) the area of the melted material in the contact area of the welded elements, i.e., projection—sheet metal, and (iii) the volume of the melted material in the welding area is described in relation to the type of the welding current (AC/DC). Selected FEM calculations were referred to experimental results. In the second step, the influence of a source type and connection method on the decrease of the welding current was determined by a circuit modelling using the FALSTAD simulation environment. The obtained results show that the voltage drop and current decrease caused by the line connections and converter structure significantly reduce the strength of the joint. For nominal parameters, i.e., welding current source (type-AC/DC), the FEM calculation results were verified experimentally. Metallographic examinations of welded joints (AC/DC) were performed and compared with the temperature distribution in the welding area for FEM.