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<p>This work addresses the challenge of temperature-sensitive joining applications in resistance welding. Considered is capacitor discharge welding of sandwich structures from two sheet metals with an interlayer of wire mesh. The intersection points of the individual loose wires form natural projections for the applied projection welding and are used for current concentration. Through the regular arrangement of projections, many individual welds with locally low heat input are created within a single pulse, which leads to a quasi-planar joint area. During the process, for each crossing point, the loose wires are welded together and the joining to the upper and lower cover sheet is also carried out. The aim of this work was to maximize the shear tensile force as a target value by varying the electrode force and energy and to identify correlations. Within the investigations, the influence of the wire mesh materials was analyzed in the form of ferritic as well as low-alloy steels. In addition, the geometry of the wire mesh was investigated by considering the wire diameter and the number of projections with respect to joint formation and joint quality. An optimized number of 50 projections were determined with shear tensile forces above 40&#xa0;kN for a X6Cr17 wire mesh. With larger connection surfaces, a wire diameter of 1.2&#xa0;mm proved advantageous compared to 1.0&#xa0;mm. The higher-density wire material X6Cr17 required less energy compared to C9D for comparable heat inputs into the joints. Target weld areas were identified and welding parameter recommendations provided.</p>

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Resistance projection welding using wire mesh inserts: Influence of material and wire mesh geometry

  • 期刊论文

  • 发表日期：

    2026年3月19日

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  • Rene Graver,
  • Nima Eslami,
  • Alexander Harms,
  • Dennis Lauterbach,
  • Stefan Boehm

摘要

This work addresses the challenge of temperature-sensitive joining applications in resistance welding. Considered is capacitor discharge welding of sandwich structures from two sheet metals with an interlayer of wire mesh. The intersection points of the individual loose wires form natural projections for the applied projection welding and are used for current concentration. Through the regular arrangement of projections, many individual welds with locally low heat input are created within a single pulse, which leads to a quasi-planar joint area. During the process, for each crossing point, the loose wires are welded together and the joining to the upper and lower cover sheet is also carried out. The aim of this work was to maximize the shear tensile force as a target value by varying the electrode force and energy and to identify correlations. Within the investigations, the influence of the wire mesh materials was analyzed in the form of ferritic as well as low-alloy steels. In addition, the geometry of the wire mesh was investigated by considering the wire diameter and the number of projections with respect to joint formation and joint quality. An optimized number of 50 projections were determined with shear tensile forces above 40 kN for a X6Cr17 wire mesh. With larger connection surfaces, a wire diameter of 1.2 mm proved advantageous compared to 1.0 mm. The higher-density wire material X6Cr17 required less energy compared to C9D for comparable heat inputs into the joints. Target weld areas were identified and welding parameter recommendations provided.