International Conference on

Advances in Materials Processing & Manufacturing Applications

iCADMA 2020
5th – 6th November 2020
Paper Id:MATPR-D-20-07986R1

Comparative Analysis of Resistance Spot welded and Weld bonded Joint of Al 6082-T651
Anand Kumar Mandal, M.L.Meena, Arun Kumar Chaudhary, Arvind Patidar, B L Gupta

Presented by: Anand Mandal

College of Technology Pantnagar

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Content
1. Introduction
2. Literature Review
3. Problem Formulation
4. Methodology
5. Results and Discussion
6. Conclusion
7. References
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Introduction

Weld Bonding is similar to resistance spot welding technique with enhanced joint strength due to
the additional adhesive layer in the overlapped region along with the weld nugget.
The process of weld bonding comprise of two techniques – Flow in and Weld through

Mittal, M. and Dwivedi, D., 2013. Studies on fatigue behaviour of weld-bonds of Al-Mn-Mg alloy.
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Literature Review
Author Title Variable Explanation
discussed

B.H.Chang et. al. A Study on the role of Thickness of the A thin adhesive layer of high elastic modulus is
adhesives in Weld-Bonded adhesive and favorable to the fatigue properties of weld-bonded
joints Elastic joints, and it is recommended as compared to
modulus of the resistance spot welded joints.
adhesive

Critical assessment of weld Weld-bonding Weld through technique has been found superior to
S.M.H. Darwish bonded technologies. techniques the flow in technique with respect to the scale of
et al. a)Weld- through production and quality of joint produced.
b) Flow-in

Analysis of The surfaces treated using sodium

manufactur ing Surface dichromate–sulphuric acid etch (CSA) and abrasive
A.M. Pereira et parameters on the shear treatment polishing (AP) resulted in improved joint shear
al. strength of aluminium
strength in comparison to the surfaces treated with
adhesive single- lap
joint s acetone cleaning (SW), caustic etch (CE), and
Tucker’s reagent etch (TR). An increase in adherent
thickness and overlap length decreases the joint
rotation angle, reducing the plastic strain peak and
therefore increasing the failure load.
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Problem Formulation

Gaps in Literature
The pattern of stress-distribution and its effect on joint strength at low pitch and high pitch distance for
both resistance spot and weld-bonded joint.
The effect of nugget diameter on stress distribution and joint strength for both resistance spot and
weld-bonded joint having multiple spots need to be looked into.
No systematic study has been made on the variation of microstructure and micro-hardness for multiple
weld-bonded and spot welded joints having nonheat treatable alumunium alloy as material
✔Comparative stress analysis of weld bonded joint and resistance spot welded joint is done using Al-6082-T651
as the testing material.
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Methodology

Experimentation is carried out optimizing weld parameters at different pitch distances for maximum
joint strength for both weld bonded and resistance spot welded joints.
Finite element model for both the weld bonded and resistance spot welded joint is developed to
further analyze the effect of pitch distance on joint strength in both cases.
The pitch distance at which both the analysis is done is 10 and 30 mm.
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Results & Discussion

Experimental Results

The failure strength of weld nugget is evaluated at pitch distance of 10mm and 30mm for both RSW and Weld
bonded joint to find that the
In RSW for the same weld parameters at pitch distance of 10 mm the maximum failure strength reached 23.6 KN
while at pitch distance of 30 mm the minimum failure strength of the joint have been 28KN and maximum strength
is 45.60 KN .
In weld bonded joint at constant weld parameters the failure strength at both the pitch distances have been 40 KN
approx.
While increase in weld nugget size shows increase in failure strength for both the weld joints.
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Results & Discussion

Finite Element Results (Resistance Spot Welded Joint)

The stress concentration is maximum at the edges of

weld nuggets.
At low pitch distance of 10mm the stress intensity of
weld nuggets superimpose each other to deteriorating
the strength of weld joint.
At higher pitch distance of 30mm there is no
superposition and also more proportion of sheet
material is available in between the two weld nuggets
to resist greater failure load.
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Results & Discussion

Finite Element Results (Weld Bonded Joint)

For weld bonded joint there is no or very less

stress concentration at the edges of weld nuggets
and the stress is distributed uniformly in the
overlapped region.

The maximum stress is developed at the end of

overlapped region. So the pitch distance no
significant effect on the strength of weld joint.
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Conclusion
The WB joint is much superior joint compared to RSW joint with minor
effect of WN pitch distance on the joint strength.
In RSW joint WN pitch distance plays a significant role deciding the
quality of joint produced.
The shunting effect of electric current is dominant at lower pitch distance
degrading the quality of joint produced for both WB and RSW joints.
Further research can be carried on finding the effect of shunting of weld
current at different pitch distances and different arrangements in both of
resistance spot welded and weld-bonded joint.
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References
1 Mittal, M. and Dwivedi, D., 2013. Studies on fatigue behaviour of weld-bonds of Al-Mn-Mg
alloy

2 Chang, B., Shi, Y. and Dong, S., 1999. Comparative studies on stresses in weld-bonded,
spot-welded and adhesive-bonded joints. Journal of Materials Processing Technology, 87(1-3),
pp.230-236.

3 Darwish, S.M.H. and Ghanya, A., 2000. Critical assessment of weld-bonded

technologies. Journal of Materials Processing Technology, 105(3), pp.221-229.

4 Pereira, A.M., Ferreira, J.M., Loureiro, A., Costa, J.D.M. and Bártolo, P.J., 2010. Effect of
process parameters on the strength of resistance spot welds in 6082-T6 aluminum
alloy. Materials & Design (1980-2015), 31(5), pp.2454-2463
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Thank You…
Q&A

Contact Details of Presenter:

anandkumarmandal.iped@gbpu
at-tech.ac.in, 8789222912 ..