A CASE STUDY ON WELDABILITY OF ALUMINUM ALLOY (AA 6082-T651) WITH RESISTANCE SPOT WELDING PROCESS WITH FEA AND ANSYS ANALYSIS

Abstract

The continuous trend of automotive weight reduction have increased focus of attention of many researchers on
weldability of Aluminum alloys with Resistance Spot Welding process for the manufacturing. Due to inferior
weld ability of Aluminum alloys for RSW, it faces a major problem of determining the optimum parameter and it
is very difficult to evaluate the welding procedure quantitatively. The aim of this study is focused on
investigation of the process parametes for RSW of aluminum alloys (AA 6082-T651) with help of ANSYS
workbench 15.0.0 software. The general resistance profile is determined by the total welding heat input.
However, the resistance is also affected by the dynamics of applied electric current, and resistance of the base
metal changes proportionally to the welding current for a very short period of time (i.e., milliseconds), this short
acting time is known as transient effect. Welding physics says that the electrical current changes faster than the
dynamic resistance of the work piece, which is the indication of accumulated heat input. This paper presents a
basic investigations with ANSYS workbench 15.0 for effect of operating parameters like electrode force,
current and cycle time 1s for a resistance spot welding process of aluminium alloy 6082-T651for the plate
thickness 1.0 mm. The RSW of aluminium alloy will ask for proper process parameters to increase its weld
quality. Aluminium alloy 6082 T651 can be a suitable replacement of AA5754 for different application with
good economy and strength. Thermal analysis shows that aluminium alloy 6082-T651 can be used for substitute
of AA5754 aluminium alloy for reduction of cost of materials in automobile industry with the application of
resistance spot welding process .