——ONLINE FIRST(NOT Peer-Reviewed)——

Title：Mist-intensified Cooling in Spot Resistance

Welding
Received：2019-03-13
Accepted：2019-03-22
Process：1、First trial(Field and check)
2、Peer review
3、Editing and three trials
4、Published online

EnPress Publisher, LLC. United States

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 Mist-intensified Cooling in Spot Resistance Welding
Z. Mikno1, B. Grzesik2, M. Stepien2

1
Welding Institute from Poland,
Bl. Czeslawa 16-18, 44-100 Gliwice, Poland, Zygmunt.Mikno@is.gliwice.pl
2
Silesian University of Technology,
B. Krzywoustego 2, 44-100 Gliwice, Poland

Key words: FEM, resistance welding, mist cooling

Abstract
The analysis being the subject of this work covers temperature distribution in welding
area (welded materials and electrodes) in classical resistance spot welding. The
paper describes a new method used for cooling welded materials and electrodes in
resistance welding by means of the so-called mist cooling. The tests incorporated
analysis and comparative calculations (FEM) for conventional cooling and a new
cooling agent i.e. water mist. The calculations were verified experimentally. The final
section contains the description of testing station and presentation of experiment
results.

Introduction
Due to high-energy emission present in resistance welding, cooling plays a very
important role in the process. During welding the temperature in the contact of welded
metals exceeds the melting point and forms the so-called nugget (Fig. 1). In case of low-
carbon steel, this temperature may be above 1500oC. Welding machine electrodes are
usually manufactured from various copper alloys. The melting point of pure copper is
considerably lower than that of steel and amounts to approx. 1083oC. However, in relation to
electrodes the critical parameter is the so-called electrode softening temperature,
significantly lower than the aforementioned copper melting point. The said parameter is
decisive for possible electrode deformation and thus determines its active life. The electrode
softening temperature is between 450oC to 500oC [2]. Due to the foregoing, electrodes
require intense cooling. A typical method of cooling both welding machine electrodes and
welded metal is cooling with water, which as a cooling medium flows through electrode
hollows (i.e. cooling ducts inside electrodes).

The cooling intensity is primarily determined by the temperature and flow of a cooling
medium. An increase in cooling intensity by increasing the flow of a cooling medium (water)
is limited due to small sizes of cooling system feeding conduits and the size of ducts
hollowed in electrodes. A major obstacle is often the size of welding machine electrodes
preventing almost physically the preparation of cooling ducts. In addition, using water as a
cooling agent (in a typical method) is connected with specific limitations. Due to limited
capacity of heat transfer in the system used so far (welded metal – electrode – water), it is
impossible to significantly increase cooling intensity in a traditional way. The critical element
is not the volume of water flowing during a welding process but, first of all, the very
phenomenon of transfer of heat from welding machine electrodes to the cooling medium
(water). In the cooling system as described above the heat of welding (in a current cycle) is
first generated in a copper electrode and then (significantly later) absorbed by the cooling
medium.

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 Fig. 1. Weld formation scheme

Classical water cooling

A common solution used for cooling electrodes and, indirectly, welded metal is water
cooling. Water flowing through welding machine electrodes cools the electrodes and, partly,
the metal being in contact with the electrode. The welded metal outside the area of contact
with the electrode is cooled indirectly by transferring heat deep into the welded metal and, to
a slight extent, to the environment.
While analysing the transfer of heat generated during welding and absorbed by the
cooling medium (water), it is necessary to take into consideration the phenomenon of heat
penetration through wall h i.e. through the (thickness of) electrode bottom (Fig. 2) separating
electrode working surface from the cooling duct. The aforesaid phenomenon can be
illustrated by equation (1) [1].

Fig. 2. Penetration of heat through electrode. a) welding machine electrode, b) electrode

tip c) heat penetration through wall – electrode bottom.

Q
 k  T  q (1)
S  t
where:

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 1
 1 h 1 
k    (2)
 12   23 
other denotations:
-  12,  23 - coefficients of heat transfer on both surfaces of wall h and
heat conductivity coefficient ,
- T = T3 - T1,
- Q - heat penetrating in time t boundary of phases of area S,
- T - temperature jump on boundary of phases,
- t – heat penetration (flow) time,
- q - surface density of heat flux.

In order to determine required quantities it is important to accurately determine

coefficients  12 and  23. It should be emphasized that there are no simple formulas for
determination of the above coefficients as their value is affected by the type and shape of a
solid body, state of surface, type of liquid, type of flow round (laminar or turbulent) and
difference of temperatures. Various empirical formulas are used to determine ; they usually
combine the impact of convection and radiation. The equation presented is related to
stabilised heat flow and does not take into account the dynamics of heat phenomena. Table
1 presents approximate coefficients of convection heat transfer.

Table 1 Coefficient  for cooling or heating of solid body [1]

Medium (W/(m2 * K))
stable air 1-50
air in motion 10-500
cooling oil 500-1500
water 200-10000

Due to difficulties connected with accurate selection of coefficients and in order to

determine actual relations it was necessary to conduct an experiment on the basis of which
it would be possible to determine the efficiency of the cooling method applied so far. In order
to get to know the phenomena of heat flow and exchange, temperatures were measured in
selected characteristic points of the object i.e. in the contact of electrode with welded metal
(Tem1) as well as in the cooling duct (Te) – Fig. 3. The experiment revealed insignificant
differences in temperature distribution in case of cooling with water and when no cooling
was applied. Therefore, the conclusion which can be drawn is that the cooling system used
so far has an insignificant effect on a resistance welding process during its course (i.e.
during a current cycle). The internal cooling system enables only the cooling of electrodes
between successive welds.

Fig. 3. Location of measurement thermocouples in tip of

welding machine electrode
A1 – 8mm

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 The electrodes themselves are capable of transferring the heat outside a welding area
not sooner than after the stoppage of welding current flow.
The obtained results proved that there was need to find other, more intensive methods
of cooling electrodes and welded metals. A new solution which could be used in resistance
welding is the so-called mist cooling. The new cooling method was analysed with reference
to heat flow. A FEM model was developed and simulations were conducted for a new
cooling medium i.e. water mist. On the basis of simulation results it was possible to design a
test station for technological trials.

Mist cooling
From technological point of view the best cooling ought to be intense and accompany
current flow preventing thus excessive heating of both electrode and welded metal
remaining in direct contact with the electrode as well as the area outside it [3].
The implementation of mist cooling method in resistance spot welding offers a new
possibility of controlling temperature distribution in welded elements. The cooling effect in
mist cooling significantly differs from that present in conventional water cooling. The new
method makes it possible to lower the temperature not only of the electrodes but also of the
surface of welded elements. Of crucial importance are vulnerable spots which are difficult to
access, such as the contact of electrode with welded metal, especially on the electrode edge.
Intense heat offtake by a cooling medium results also in more convenient temperature
distribution in the whole welding area. An additional advantage is related to better shaping of
a nugget, whose height, especially in outer areas, is lower. More advantageous temperature
distribution results in lower plastification of welded metals, which in turn, reduces the depth
of electrode indents in welded metals and enables maintaining protective, e.g. zinc, coating
on welded metal surface.
In order to locate intensively
heated spots and, at the same time,
accessible for the new cooling
method, it was necessary to
conduct FEM simulations of a
welding process. The simulations
made it possible to determine
losses in a copper cone of side
surface of 5mm and wall thickness
of 0.3mm as well as in a steel ring
of inner diameter of 6mm, outer
diameter of 16mm and 0.3mm in
thickness (Figure 4). Such surfaces
Fig. 4. Intensity of electrode and welded may be exposed to new mist
metal heating (FEM simulations) cooling method consisting in
turning water mist into vapour.

As a result of intensified
cooling of surface of welded metals, it is possible to observe a decrease in the temperature
outside the contact area between the electrode and welded metal as well as outside outer
electrode surfaces. This fact has a significant influence on current density distribution as well
as on welding power and temperature, which in turn, directly affects weld formation.
Higher cooling intensity results from considerably higher heat of water mist vaporisation
(steam) in relation to the specific heat of water commonly used in welding machines as a
cooling medium. In addition, there is a different mechanism of heat exchange than in case of
the traditional method (welded metal – copper electrode – water) having limited possibilities
of heat offtake during a current cycle. Water mist falls directly on welded metal and although
less intensively heated spots are subject to cooling, the effectiveness of the method is clearly
visible (Fig. 5).

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 Fig. 5. Mist cooling-related comparison of calculations (FEM model) with experiment.
Upper part was subject to mist cooling, lower part was cooled traditionally (with
internal water) (i = 8 kA, tzgrz = 320 ms)

In order to contrast calculations and experiment, their results were compared. In the
experiment only the upper element was subject to cooling so that the efficiency of mist
cooling could be clearly demonstrated The cooled elements were made of 1.5mm-thick 08X-
grade steel. The part subject to mist cooling (upper part) demonstrates better temperature
distribution, in particular, on the edge of the contact between electrode and welded metal.
As can be seen from smaller indents left by the electrode in the welded metal (upper part),
mist cooling also affects the temperature in the contact between electrode and welded
material. The obtained results can also be confirmed by FEM calculations (Fig. 6 and 7;
temperature distribution in the contact between the electrode and welded metal).

Fig. 6. Temperature distribution in the Fig. 7. Temperature distribution in the

contact between electrode and welded
metal in case of typical cooling with
water for, accordingly, 25, 50, 75 and
100 % of welding time (T025, T050, T075,
T100).
contact between electrode and welded
metal in case of mist cooling for,
accordingly, 25, 50, 75 and 100 % of
welding time (T025, T050, T075, T100).

In case of traditional cooling method, heat energy emitted in the contact between
electrode and welded metal is higher, particularly, in the final phase of welding. In case of
mist cooling the temperature in the contact between the electrode and welded metal, as well
as in neighbouring areas, is lower and so are the resistance values of the contact and metal
in the aforesaid areas, which in turn, prevents heat generation in these places.

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 Fig. 8. Course of power in selected Fig. 9. Course of power in selected
locations (Fig. 10) for typical cooling locations (Fig. 10) for mist cooling
(with water)

Also the time-related (volumetric) power distribution in the selected points of welding
area (Figures 8, 9 and 10) is advantageous. In the points situated in the surface of the
contact between the electrode and welded metal it is possible to observe a lower increase in
power caused by faster offtake of heat from this area. Intensified cooling in the area is
beneficial. The temperature in the area is lower and thus reduces its resistance and
generation of Joule’s heat. The intensity of mist cooling is so strong that it also reduces the
temperature present in the nugget.

Fig. 10. Geometrical model of resistance

welding used for FEM simulation (with
selected measurement points marked red)

Description of experiments
Figure 11 presents the position of sprayers (on a mounting ring) in relation to the
welding machine electrode. In order to obtain explicit experimentation results, cooling was
performed only from one side. The sprayers were made from typical fuel injection units used
in motor-car engines. Their efficiency, spraying and electronic control feature enabled the
performance of tests within a working pressure range up to 20 bars.

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 Fig. 11. Location of sprayers on mounting
ring

Fig. 12. Outside view of materials after a

welding process; visible marks left by
welding machine electrodes (I = 8 kA,
tzgrz = 320 ms)

The effect of mist cooling can be observed in the outer view of a weld. Figure 12 shows
the outer post-welding view of materials with visible marks left by the welding machine
electrodes.
The figures present the surfaces of welded metals after a welding process. The
surfaces are provided with visible marks left due to pressure exerted by the electrodes and
with welded metal colouring around the electrodes caused by temperature exceeding 700oC.
The left-hand side of the figure presents the outer view of welded metal after welding with
regular (outside) water cooling. The right-hand side of the figure shows the result of
additional impact of mist cooling. For the sake of better presentation, the experiments were
conducted for the soft power parameters of the process (I = 8 kA, tzgrz = 320 ms) as opposed
to typically used (I  10 kA, tzgrz  200 ms). For nominal conditions, the impact of this cooling
was less distinct.

Summary
Mist cooling can be used in continuous welding processes, particularly in linear welding,
in which cooling is applied both for welded metals and electrodes. Due to a high process
speed, this kind of welding cannot always be performed effectively with the use of standard
internal cooling of electrodes.

References:
[1] Mizerski W. Praca zbiorowa Tablice fizyczno-astronomiczne, wydawnictwo Admantan,
W-wa 2002, wydanie II.
[2] Papkala H.: Zgrzewanie oporowe metali, wydawnictwo KaBe Krosno 2003.
[3] Mikno Z.: Analiza procesu sterowania przestrzennym rozkładem mocy zgrzewania
rezystancyjnego. Praca doktorska. Politechnika Śląska, Wydział Elektryczny, promotor
prof. B. Grzesik, 2005 r.

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