Abstract Dynamic electrical resistance during resistance spot welding has been quantitatively modeled and analyzed in this work. A determination of dynamic resistance is necessary for predicting the transport processes and monitoring the weld quality during resistance spot welding. In this study, dynamic resistance is obtained by taking the sum of temperature dependent bulk resistance of the workpieces and contact resistances at the faying surface and electrode-workpiece interface within an effective area corresponding to the electrode tip where welding current primarily flows. A contact resistance is composed of constriction and film resistances, which are functions of hardness, temperature, electrode force, electrical resistivity and surface condition. Unsteady, axisymmetric transport of mass, momentum, energy, species, and magnetic field intensity with a mushy-zone phase change in workpieces and temperature, and magnetic fields in electrodes during resistance spot welding, are systematically investigated. Electromagnetic force, joule heat, heat generation at the electrode-workpiece interface and faying surface between workpieces, different properties between phase, and geometries of electrodes are taken into account. The predicted nugget thickness and dynamic resistance versus time show quite good agreement with available experimental data. Excluding expulsion, the dynamic resistance curve can be divided into four stages. A rapid decrease of dynamic resistance in stage 1 is attributed to decreases in film resistances at the faying surface and electrode-workpiece interface. In stage 2, the increase in dynamic resistance results from the primary increase of bulk resistance in the workpieces and an increase of the sum of contact resistances at the faying surface and electrode-workpiece interface. Dynamic resistance in stage 3 decreases, because increasing rate of bulk resistance in the workpieces and contact resistances decrease. In stage 4 decrease of dynamic resistance is mainly due to the formation of the molten nugget at the faying surface. The molten nugget is found to occur in stage 4 rather than stage 2 or 3 as qualitatively proposed in the literature. The effects of different parameters on the dynamic resistence curve are also presented. Besides, electromagnetic force effect on velocity field of molten nugget was proven to be crucial. Higher current, smaller magnetic diffusivity and decreasing the radius of electrode tip will lead to high current density around the corner between electrode and workpiece. Sometimes the corner of electrode and surface of workpieces will be melted due to local high current density.

<p>Within the framework of presented PhD, friction stir spot welding (FSSW) of<br />multiple ultrathin sheets of AA 5754 &ndash; H111 (AlMg3) alloy 0.3 mm thick, was<br />studied. The influence of tool geometry and process parameters such as rotational<br />speed and axial load have been analysed using numerous techniques. It has been<br />understood that during the welding at low rotational speeds weld zone undergoes<br />strain hardening, while at high rotational speeds weld zone undergoes thermal<br />softening. It was observed that during FSSW at low rotational speeds a complex<br />layer at weld interface is present, which causes delamination when welded samples<br />are subjected to load.</p> / <p>У оквиру ове докторске дисертације испитивано је тачкасто заваривање трењем са мешањем ултратанких лимова дебљине 0.3 mm од легуре АА 5754 &ndash; H111 (AlMg3). Утицај геометрије алата и параметара као што су угаона брзина и аксијално оптерећење су детаљно анализирани уз помоћ бројних техника. Установљено је да приликом заваривања ниским угаоним брзинама долази до деформационог ојачавања, док на високим угаоним брзинама долази до термичког омекшавања зоне завара. Код узорка завареног са најмањим бројем обртаја долази до формирања комплексног слоја на међуконтактној површини који изазива деламинацију приликом испитивања механичких особина.</p> / <p>U okviru ove doktorske disertacije ispitivano je tačkasto zavarivanje trenjem sa mešanjem ultratankih limova debljine 0.3 mm od legure AA 5754 &ndash; H111 (AlMg3). Uticaj geometrije alata i parametara kao što su ugaona brzina i aksijalno opterećenje su detaljno analizirani uz pomoć brojnih tehnika. Ustanovljeno je da prilikom zavarivanja niskim ugaonim brzinama dolazi do deformacionog ojačavanja, dok na visokim ugaonim brzinama dolazi do termičkog omekšavanja zone zavara. Kod uzorka zavarenog sa najmanjim brojem obrtaja dolazi do formiranja kompleksnog sloja na međukontaktnoj površini koji izaziva delaminaciju prilikom ispitivanja mehaničkih osobina.</p>