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Multi-signal quality monitoring of aluminium resistance spot welding using principal component analysis

Summerville, Cameron; Adams, David; Compston, Paul; Doolan, Matthew

Description

The current migration to lighter materials in car bodies, such as aluminium, has resulted in significant challenges for joining in production. Resistance Spot Welding (RSW) is the primary sheet metal joining technique in the automotive industry due to its quick cycle time, low cost and high strength. However, aluminium RSW suffers from problems with quality consistency compared to steel, requiring more frequent interventions. This results in a higher cost in production through increased cycle...[Show more]

dc.contributor.authorSummerville, Cameron
dc.contributor.authorAdams, David
dc.contributor.authorCompston, Paul
dc.contributor.authorDoolan, Matthew
dc.date.accessioned2018-06-05T00:05:03Z
dc.identifier.citationSummerville, C; Adams, D; Compston, P and Doolan, M. Multi-signal quality monitoring of aluminium resistance spot welding using principal component analysis [online]. In: 9th Australasian Congress on Applied Mechanics (ACAM9). Sydney: Engineers Australia, 2017: [684]-[691]. Availability: <https://search.informit.com.au/documentSummary;dn=394452759571556;res=IELENG> ISBN: 9781925627022. [cited 04 Jun 18].
dc.identifier.isbn9781925627022
dc.identifier.urihttp://hdl.handle.net/1885/143869
dc.description.abstractThe current migration to lighter materials in car bodies, such as aluminium, has resulted in significant challenges for joining in production. Resistance Spot Welding (RSW) is the primary sheet metal joining technique in the automotive industry due to its quick cycle time, low cost and high strength. However, aluminium RSW suffers from problems with quality consistency compared to steel, requiring more frequent interventions. This results in a higher cost in production through increased cycle times and the use of consumable electrodes. To address this issue, a new multi-signal quality monitoring technique is proposed to allow for complete real-time quality monitoring of aluminium spot welds in production. The proposed solution utilises multiple signals during welding and an efficient algorithm using Principal Component Analysis to determine the signal shapes of interest. It was found that an RMSE of 119N could be achieved when predicting the strength of aluminium spot welds using multiple signals, which is approximately ±5% of the mean strength of the welds and an improvement on previous attempts.
dc.description.sponsorshipThis research was supported by an Australian Government Research Training Program (RTP) Scholarship.
dc.format.mimetypeapplication/pdf
dc.publisherEngineers Australia
dc.relation.ispartof9th Australasian Congress on Applied Mechanics (ACAM9)
dc.rights© The Author(s)
dc.source.urihttps://search.informit.com.au/documentSummary;res=IELENG;dn=394452759571556
dc.subjectResistance Spot Welding
dc.subjectAluminium
dc.subjectQuality Monitoring
dc.subjectPrincipal Component Analysis
dc.subjectFailure Analysis
dc.titleMulti-signal quality monitoring of aluminium resistance spot welding using principal component analysis
dc.typeConference paper
dc.date.issued2018-03
local.identifier.ariespublicationu4485658xPUB460
local.publisher.urlhttps://search.informit.com.au/documentSummary;res=IELENG;dn=394452759571556
local.type.statusAccepted Version
local.contributor.affiliationSummerville, Cameron, The Australian National University
local.bibliographicCitation.startpage684
local.bibliographicCitation.lastpage691
dcterms.accessRightsOpen Access
dc.provenanceThe publisher permission to archive the version was granted via email, archived in ERMS
CollectionsANU Research Publications

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