Inspection and Testing

Peel Test
Shown in the figure:

Radiography
[Drawbacks] The time element in developing the negative and obtaining the necessary information Impracticability of taking the welded parts to the X-ray machine with the attendant time element involved Not all faults are revealed Interpretation of radiographs requires a highly skilled technician

Visual Inspection

Peel Test and Chisel Test

Button Size as a Measure of Weld Quality

Button Diameter

Modes of Failure in Spot Welds

Full Button

Irregular Button

Interfacial Failure

Long Life Test

-- on 1.3-mm Thick 6009-T4 Arc Cleaned/Conversion-Coated Sheet with Truncated Cone Electrodes and Current Stepping
Percent Heat (%) Undersized Button Buttons/Strip Diameter (mm)

[Reference: SAE 840291, Patrick, Auhl, and Sun]

Number of Welds

Shear-Strength Data for Long Life Test

-- on 6009-T4 Arc Cleaned/Conversion-Coated Sheet

Shear Strength (kN/Spot)

[Reference: SAE 840291, Patrick, Auhl, and Sun]

Number of Welds

Minimum Tensile-Shear Strength of Spot Welds in Aluminum Alloys

[Reference: Resistance Welding Manual, p.11-26, RWMA]

Resistance Spot Weld Radiographs 1 mm Sheet

6009/6009

5182/5182

2036/2036

Small Cracking

Large Center Porosity

Large Cracking

[Reference: Joining of Aluminum Alloys 6009/6010, Hoch]

Types of Defects Revealed by Radiography

Undersize nugget
Inadequate diameter Inadequate penetration

Cracking of the nugget Porosity Expulsion from faying surfaces Segregation of eutectic in parent material Electrode pickup Size or extent or granular zone Nugget penetration

Oversize nugget
Excessive diameter Excessive penetration

Odd and misshapen nuggets Extent of Alclad inclusion into the nugget Extrusion of the nugget

Setup Procedures and Suggested Schedules

[Step 1] Insert electrode of proper size and tip contour for the gauge combination. Align electrodes. [Step 2] Set pressure gage for suggested welding force, and check with an electrode force gauge. [Step 3] Adjust the control to provide the approximate suggested weld and postheat time. [Step 4] The welding currents shown are approximate and intended to be a guide. The magnitude of the welding current is usually controlled by a heat dial or phase-shift control. [Step 5] Check the machine for consistency of operation by making and testing twenty single spot tension-shear specimens and five macroscopic examination specimens.

Typical Oscillograph Record during Welding

Voltage

1V
Force 1 kN 0.25 mm Displacement Forge Force

Welding Force

Current
5.0 kA rms 0.1 sec

Typical Oscillograph Record

5.2 kA RMS

Current

0.7 kN

Force

0.2 mm

Displacement
1.0 V (p-t-p)

Zero line for force

Voltage

Resistance Spot Weld Data

[Reference: Guidelines to Resistance Spot Welding Aluminum Automotive Sheet, p.9, The Aluminum Association]

Shunting Effect on 2024-T Alclad

Shunt Path Resistance, Microohms
Joint Strength, lb/weld

Factors Influencing Shunting Effect Include: Thickness and resistance of the alloy being welded
Shunting effect increases as the stock thickness and resistance decrease

Joint Strength Shunt Resistance

Weld Spacing, in.

Surface resistance [Reference: Resistance Welding Manual, p.11-19, RWMA]

of

Suggested Minimum Weld Spacing Edge and Flange Distance

[Reference: Resistance Welding Manual, p.11-20, RWMA]