Performance of resistance spot weld caps coated with Ni and Fe aluminide alloys by electro spark deposition on hot dip galvanized steel

Authors

DOI:

https://doi.org/10.3989/revmetalm.237

Keywords:

Electro-spark deposition, Hot dip galvanized steel, Iron aluminides, Nickel aluminides, Resistance spot welding

Abstract


Resistance spot welding (RSW) is widely used as a main joining technique in industry and the electrode caps are frequently replaced because of the degradation during service. In this study, the G type copper RSW electrode caps were coated with Fe and Ni based Fe3Al, FeAl, Ni3Al, NiAl alloys by Electro-Spark Deposition (ESD), providing resistance to hot deformation, oxidation and Zn evaporation from sheet metal. The ESD coated electrode caps were tested in-situ on a hot dip galvanized steel in order to assess the performance of RSW electrode caps. For this purpose, three different coating voltages were selected for each coated electrode, and 12 different cap coatings were produced in total. Fifty resistance spot welds were consecutively manufactured with the same parameters for each type of coating electrodes. Hardness measurements, macrostructural examination, Ultrasonic Testing (UT) and chisel tests were performed on welded samples produced. In addition, effects of different coatings on RSW electrode caps were investigated on microstructural development, hardness variations and deformation capacity of resistance spot welds. Results showed that chisel tests and cross section thickness values of the welded sample made with the caps that were ESD coated with the Ni3Al electrode produced better results than the other caps. The cross-sectional thickness of nuggets was lower in all 158 V coated caps. The performance of aluminide coatings on RSW electrode caps can be listed from the best to the worst in the order of Ni3Al, NiAl, Fe3Al, and FeAl.

Downloads

Download data is not yet available.

References

Aslanlar, S. (2006). The effect of nucleus size on mechanical properties in electrical Resistance Spot Welding of sheets used in automotive industry. Mater. Des. 27, 125-131. https://doi.org/10.1016/j.matdes.2004.09.025

Athi, N., Cullen, J.D., Al-Jader, M., Wylie, S.R., Al-Shamma'a, AI., Shaw, A., Hyde, M. (2009). Experimental and theoretical investigations to the effects of zinc coatings and splash on electrode cap wear. Measurement 42, 944-953. https://doi.org/10.1016/j.measurement.2009.02.001

Bhattacharya, D. (2018). Liquid metal embrittlement during resistant spot welding of Zn-coated high-strength steels. Mater. Sci. Technol. 34 (15), 1809-1829. https://doi.org/10.1080/02670836.2018.1461595

Biliz, İ., Bakkaloglu, A., Kilic, M. (2020). The effect of process parameters on microstructure and porosity of layered NiAl(Co/Cr) alloy produced by SHS method. J. Polytech. 23 (1), 161-169. https://doi.org/10.2339/politeknik.557592

Bozkurt, A., Çakmakkaya, M., Çetkin, A., Talaş, Ş. (2016). Heat transfer and electrical characteristics in spot welding with composite coated caps. Proc. International Conference on Welding Technologies and Technology, (ICWET'16), Ankara.

Bozkurt, B., Emre Ertek, H., Kaçar, R. (2018). Effect of Electrodes Coated with Different Materials by Electrospark Method on the Resistance Spot Weld Quality. Int. J. Sci. Eng. Res. 9 (8), 81-86. https://www.ijser.org/researchpaper/Effect-of-Electrodes-Coated-with-Different-Materials-by-Electrospark-Method-on-the-Resistance-Spot-Weld-Quality.pdf.

Chen, Z., Zhou, Y. (2006). Surface modification of resistance welding electrode by electro-spark deposited composite coatings: Part I coating characterization. Surf. Coat. Technol. 201 (3-4), 1503-1510. https://doi.org/10.1016/j.surfcoat.2006.02.015

Choi, H.S., Park, G.H., Lim, W.S., Kim, B.M. (2001). Evaluation of weldability for resistance spot welded single-lap joint between Ga780DP and hot-stamped 22MnB5 steel sheets. J. Mech. Sci. Technol. 25, 1543-1550. https://doi.org/10.1007/s12206-011-0408-x

Demirbilek, O., Onan, M., Ünlü, N., Talaş, Ş. (2022). Investigation of the efficiency for ESD coating with stainless steel on die surfaces. Int. J. Surf. Sci. Eng. 16 (4), 335-348. https://doi.org/10.1504/IJSURFSE.2022.127071

Gould, J. (2011). Application of electro-spark deposition as a joining technology. Weld. J. 90 (10), 191-197.

Harlin, N., Jones, T.B., Parker, J.D. (2003). Weld growth mechanism of resistance spot welds in zinc coated steel. J. Mater. Process. Technol. 143-144, 448-453. https://doi.org/10.1016/S0924-0136(03)00447-3

Holliday, R., Parker, J.D., Williams, N.T. (1995). Electrode deformation when spot welding coated steels. Weld. World. 35 (3), 160-164.

Judkins, R.R., Rao, U.S. (2000). Fossil energy applications of intermetallic alloys. Intermetallics 8 (9-11), 1347-1354. https://doi.org/10.1016/S0966-9795(00)00110-2

Kaiser, J.G., Dunn, G.J., Eagar, T.W. (1982). The effect of electrical resistance on nugget formation during spot welding. Weld. J. 62 (6), 167s-174s. https://eagar.mit.edu/publications/Eagar026.pdf.

Korkmaz, K. (2015). Investigation and characterization of electrospark deposited chromium carbide-based coating on the steel. Surf. Coat. Technol. 272, 1-7. https://doi.org/10.1016/j.surfcoat.2015.04.033

Korkmaz, K., Ribalko, A.V. (2011). Effect of pulse shape and energy on the surface roughness and mass transfer in the electrospark coating process. Metallic Mater. 49 (4), 265 - 270. https://doi.org/10.4149/km_2011_4_265

Krein, R., Schneider, A., Sauthoff, G., Frommeyer, G. (2007). Microstructure and mechanical properties of Fe3Al - based alloys with strengthening boride precipitates. Intermetallics 15 (9), 1172-1182. https://doi.org/10.1016/j.intermet.2007.02.005

Li, W., Cheng, S., Hu, S.J., Shriver, J. (2001). Statistical investigation on RSW quality using a two-stage, sliding-level experiment. ASME J. Manuf. Sci. Eng. 123 (3), 513-520. https://doi.org/10.1115/1.1382595

Luo, Y., Wan, R., Yang, Z., Xie, X. (2016). Study on the thermo-effect of nugget growing in single-phase AC resistance spot welding based on the calculation of dynamic resistance. Measurement 78, 18-28. https://doi.org/10.1016/j.measurement.2015.09.034

Masset, P., Texier, D., Schütze, M. (2009). Coefficients of thermal expansion of (Ni0.5Al0.5) (1-x)Hfx alloys (x= 0...0.2). Mater. Sci. Technol. 25 (7), 874-879. https://doi.org/10.1179/174328408X372083

Mertgenç, E., Talaş, Ş., Gökçe, B. (2019). The wear and microstructural characterization of copper surface coated with TiC reinforced FeAl intermetallic composite by ESD method. Mater. Res. Express 6 (11), 1165e7. https://doi.org/10.1088/2053-1591/ab507e

Mikno, Z, Bartnik, Z. (2016). Heating of electrodes during spot resistance welding in FEM calculations. Arch. Civ. Mech. Eng. 16 (1), 86-100. https://doi.org/10.1016/j.acme.2015.09.005

Morris, D.G., Munoz-Morris, M. (2005). The stress anomaly in FeAl-Fe3Al alloys. Intermetallics 13 (12), 1269-1274. https://doi.org/10.1016/j.intermet.2004.08.012

Onan, M., Şahin, O., Yıldırım, E., Talaş, Ş. (2022). Effect of WC based coatings on the wear of CK45 sheet metal forming dies. Int. J. Surf. Sci. Eng. 15 (4), 265-280. https://doi.org/10.1504/IJSURFSE.2021.120959

Parkansky, N., Boxman, R.L., Goldsmith, S. (1993). Development and application of pulsed-air-arc deposition. Surf. Coat. Technol. 61 (1-3) 268-273. https://doi.org/10.1016/0257-8972(93)90237-I

Rogeon, P., Carre, P., Costa, J., Sibilia, G., Saindrenan, G. (2008). Characterization of electrical contact conditions in spot welding assemblies. J. Mater. Process. Technol. 195 (1-3), 117-124. https://doi.org/10.1016/j.jmatprotec.2007.04.127

Schaefer, H-E., Frenner, K., Würschum, R. (1999). High temperature atomic defect properties and diffusion processes in intermetallic compounds. Intermetallics 7 (3-4), 277-287. https://doi.org/10.1016/S0966-9795(98)00121-6

Song, Q., Zhang, W., Bay, N. (2005). An experimental study determines the electrical contact resistance in resistance welding. Weld. J. 84 (5), 73s-76s.

Stoloff, N., Liu, C., Deevi, S. (2000). Emerging applications of intermetallics. Intermetallics 8 (9-11), 1313-1320. https://doi.org/10.1016/S0966-9795(00)00077-7

Švec, M., Hanus, P., Vodičková, V. (2013). The coefficient of thermal expansion of Fe3Al and feal - type iron aluminides. Manuf. Technol. 13 (3), 399-404. https://doi.org/10.21062/ujep/x.2013/a/1213-2489/MT/13/3/399

Talaş, Ş. (2018). Nickel Aluminides. in, Intermetallic matrix composites. R. Mitra (Ed.), Woodhead Publishing, pp. 37-69. https://doi.org/10.1016/B978-0-85709-346-2.00003-0

Tang, S.K., Nguyen, T.C., Zhou, Y. (2010). Materials transfer in electro-spark deposition of TiCp/Ni metal-matrix composite coating on Cu substrate. Weld. J. 89 (8), 172s-180s.

Terada, Y., Ohkubo, K., Mohri, T., Suzuki, T. (2002). Thermal conductivity of intermetallic compounds with metallic bonding. Mater. Trans. 43 (12), 3167-3176. https://doi.org/10.2320/matertrans.43.3167

Tortorelli, P., Natesan, K. (1998). Critical factors affecting the high temperature corrosion performance of iron aluminides. Mater. Sci. Eng. A 258 (1-2), 115-125. https://doi.org/10.1016/S0921-5093(98)00924-1

Wan, X., Wang, Y., Zhang, P. (2014). Modelling the effect of welding current on RSW of DP600 steel. J. Mater. Process. Technol. 214 (11), 2723-2729. https://doi.org/10.1016/j.jmatprotec.2014.06.009

Wang, K., Reeber, R.R. (1996). Thermal expansion of copper. High Temp. Mater. Sci. 35, 181-186.

Wang, Y., Liu, Z-K., Chen, L-Q. (2004). Thermodynamic properties of Al, Ni, NiAl, and Ni3Al from first-principles calculations. Acta Mater. 52 (9), 2665-2671. https://doi.org/10.1016/j.actamat.2004.02.014

Williams, N.T., Parker, J.D. (2004). Review of resistance spot welding of steel sheets Part 1: modelling and control of weld nugget formation. Int. Mater. Rev. 49 (2), 45-75. https://doi.org/10.1179/095066004225010523

Zhang, X.Q., Chen, G.L., Zhang, Y.S. (2008). Characteristics of electrode wear in RSW dual-phase steels. Mater. Des. 29 (1), 279-283. https://doi.org/10.1016/j.matdes.2006.10.025

Published

2023-04-27

How to Cite

Açış, İbrahim F. ., & Talaş, Şükrü. (2023). Performance of resistance spot weld caps coated with Ni and Fe aluminide alloys by electro spark deposition on hot dip galvanized steel. Revista De Metalurgia, 59(1), e237. https://doi.org/10.3989/revmetalm.237

Issue

Section

Articles