Surface modified long-life electrode for resistance spot welding of Zn-coated steel |
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| Authors: | Jiasheng Zou Qizhang Zhao Zheng Chen |
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| Affiliation: | 1. Division of Materials and Manufacturing Science, Graduate School of Engineering, Osaka University, 2-1 Yamadaoka, Suita, Osaka 575-0871, Japan;2. Joining and Welding Research Institute, Osaka University, 11-1 Mihogaoka, Ibaraki, Osaka 567-0047, Japan;1. Department of Materials Engineering, Isfahan University of Technology, Isfahan 84156-83111, Iran;2. Department of Advanced Materials Engineering, Dong-Eui University, Busan 614-714, Korea;3. Department of Materials Science & Engineering, The Ohio State University, Columbus, OH 43221, USA;4. POSCO Technical Research Laboratories, Gwangyang 545-090, Korea;1. Shenyang National Laboratory for Materials Science, Institute of Metal Research, Chinese Academy of Sciences, Shenyang 110016, China;2. Key Laboratory of Automobile Materials, Ministry of Education, School of Materials Science and Engineering, Jilin University, Changchun 130022, China;3. Department of Product Management, FAW-Volkswagen Automobile Co. Ltd., Changchun 130011, China;4. Department of Technology, FAW Car Co. Ltd., Changchun 130012, China |
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| Abstract: | In order to increase the life of conventional copper electrodes in resistance spot welding of Zn-coated sheet steel, a multi-layer Ni/(TiCP/Ni)/Ni composite coating was deposited onto the copper electrode top surface by electro-spark deposition. Scanning electron microscopy, energy dispersive X-ray analysis, X-ray diffraction and micro-hardness tests were employed to characterize the microstructure and property of the coating. The results showed that the copper electrodes with a dense Ni/(TiCP/Ni)/Ni coating slightly increased the resistance of the weld system and hence the welding current could be reduced to produce a weld with the same button size as that made by uncoated electrodes at a high welding current. The coating was gradually cracked during welding under the action of welding force, forming Ni/(TiCP/Ni)/Ni composite islands which were strongly adherent to and further, punched into copper substrate. The coating could significantly reduce the alloying between copper electrode substrate and molten Zn. As a result, coated electrode showed a much longer life than an uncoated electrode even though the welding current for coated electrode was lower than that for uncoated one. |
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