Ultrasonic in-process characterization of resistance spot welds has many advantages over off-line methods, particularly adding the ability to inspect more than 99% of the parts that would otherwise go unchecked. In addition, real-time monitoring of the process can identify problems that occur and allow control engineers to correct these problems before additional bad parts are produced. An example of a damaged watercooling pipe is illustrated in this article. Use of the real-time integrated weld analyzer (RIWA) system provides an opportunity to automatically correct bad welds and prevent them in the future product. The inline ultrasound inspection system installed in the Windsor Assembly Plant provides the capability to observe the process of weld formation as well as identify expulsion. Parameters such as the moment of melting, liquid metal penetration depth, solidification, and cooling rates are used for quality characterization of every weld done at the installed unit. In addition, statistics of weld quality over time are monitored from which data regarding electrode wear and process degradation can be inferred. Such a tool is proving to be effective in the harsh industrial environments of the automotive assembly plant, and the benefits of such thorough quality inspection are immediately clear.
In-line inspection of resistance spot welds for sheet metal assembly
Welding Journal, New York ; 93 , 1 ; 58-62
2014
5 Seiten, 11 Bilder, 13 Quellen
Aufsatz (Zeitschrift)
Englisch
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