Numerical Analysis of Coaxial One-Side Resistance Spot Welding between Al5052 and CFRP

REN Sendong; CHEN Hao; SHEN Yihao; YANG Jianguo

doi:10.7512/j.issn.1001-2303.2024.08.06

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Numerical Analysis of Coaxial One-Side Resistance Spot Welding between Al5052 and CFRP
Vol. 54, Issue 8, Pages: 45-50(2024)
Received：31 May 2024，

Published：25 August 2024
DOI： 10.7512/j.issn.1001-2303.2024.08.06
稿件说明：

移动端阅览

任森栋，陈浩，沈毅豪，等.Al5052-CFRP同轴单边电阻点焊的数值分析［J］.电焊机，2024，54（8）：45-50. DOI： 10.7512/j.issn.1001-2303.2024.08.06.

REN Sendong, CHEN Hao, SHEN Yihao, et al.Numerical Analysis of Coaxial One-Side Resistance Spot Welding between Al5052 and CFRP[J].Electric Welding Machine, 2024, 54(8): 45-50. DOI： 10.7512/j.issn.1001-2303.2024.08.06.

摘要

文中提出了一种新型的同轴单边电阻点焊技术用于连接Al5052和碳纤维增强复合材料（CFRP）。基于内部有限元代码JWRIAN-RSW对同轴单边电阻点焊的“电-热-力”耦合过程进行数值建模，预测焊接热循环与温度分布并进行了实验验证。采用十字拉伸实验评价了接头的力学性能，分析了焊接参数对连接强度、失效行为和界面特征的影响。讨论了同轴单边电阻点焊熔化区尺寸的生长过程与机理。结果表明，实验测得的焊接热循环与数值预测结果吻合较好，证明了所开发的数值模型的有效性；焊接接头呈现出两种断裂模式：焊接电流较小时，连接强度较弱，接头沿Al5052-CFRP界面失效，呈现出脆性断裂的特征，最大载荷约为170 N，焊接电流较大时，局部失效发生在CFRP基体，接头呈现出韧性断裂特征，力学性能大幅提升，载荷峰值提升至1 335 N。此外，Al5052-CFRP同轴单边电阻点焊的熔化区在冷却阶段初期仍会持续增长。因此，对同轴单边电阻点焊的数值建模必须考虑到冷却阶段，通过峰值温度分布来预测熔化区的尺寸。

Abstract

Coaxial one-side resistance spot welding (COS-RSW) is an advanced method of joining metal and carbon fibre reinforced plastic (CFRP). In the present research

the author-developed finite element code JWRIAN-RSW was employed to model the electrical-thermal-mechanical coupled phenomena of COS-RSW between Al5052 and CFRP. The welding thermal cycle was predicted numerically and verified by experimental measurement. Cross-tension test was used to evaluate the mechanical performance of joints

the influence of welding parameters on joining strength

fracture behaviours and interface morphology was clarified. The generation of molten zone dimension was also discussed. The results showed that the predicted thermal cycle presented a good agreement with measurement

which indicated the effectiveness of numerical model. The COS-RSW joints presented two fracture modes. Low welding current resulted in a weak joining

interfacial failing and brittle fracture. The large current led to a strong bonding and ductile fracture

the failure occurred within the resin matrix. Besides

the molten zone of COS-RSW can grow up even in the early stages of cooling. Therefore

it was necessary to consider the cooling stage in the numerical model of COS-RSW to predict the molten zone dimension via peak temperature distribution.

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