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resistance spot welding

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Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.aero.c0047673
EISBN: 978-1-62708-217-4
...Abstract Abstract A series of resistance spot welds joining Z-shape and C-shape members of an aircraft drop-tank structure failed during ejection testing. The members were fabricated of alclad aluminum alloy 2024-T62. The back surface of the C-shape members showed severe electrode-indentation...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.aero.c0047677
EISBN: 978-1-62708-217-4
...Abstract Abstract Resistance spot welds joining aluminum alloy 2024-T8511 stiffeners to the aluminum alloy 6061-T62 skin of an aircraft drop tank failed during slosh and vibration testing. Visual examination of the fracture surfaces showed that the failure was by tensile or bending overload...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.auto.c9001612
EISBN: 978-1-62708-218-1
...Abstract Abstract The fan used to cool a diesel engine fractured catastrophically after approximately 100 h of operation. The fan failed at a spider, which was resistance spot welded to a shim placed between two circular spiders of 3 mm thickness. The detailed analysis of the fracture indicated...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.auto.c9001514
EISBN: 978-1-62708-218-1
... forward. Although not contributory to the accident itself, the faulty welds were responsible in part for the severity of the injuries sustained by the driver. The faulty welds in the unit body were apparently a consequence of improper settings of parameters on a multihead electrical resistance spot...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.mech.c0047935
EISBN: 978-1-62708-225-9
... the spot was evidenced to have been melted and welded to the inner-ring raceway. It was revealed by randomly spaced welded areas on the raceways that the welding was the result of short electrical discharges between the bearing raceways and the balls. The use of an electrically nonconductive lubricant...
Series: ASM Failure Analysis Case Histories
Volume: 1
Publisher: ASM International
Published: 01 December 1992
DOI: 10.31399/asm.fach.v01.c9001047
EISBN: 978-1-62708-214-3
... joining the tube sheet to the floating skirt. Cracks penetrated deep into the tube sheet, and occasionally into the tube walls. The microstructures of both alloys and of the weld appeared normal. Intergranular corrosion characteristic of end-grain attack was apparent. A low dead spot at the skirt / tube...
Series: ASM Failure Analysis Case Histories
Volume: 1
Publisher: ASM International
Published: 01 December 1992
DOI: 10.31399/asm.fach.v01.c9001028
EISBN: 978-1-62708-214-3
...-up with the endcap, then clamped to the inside of the endcap prior to resistance spot welding in the areas shown in Fig. 1 . The top of the internal vent tube terminates at a controlled distance just below the inside top surface of the endcap/tank. The endcap/baffle/tube assembly is attached...
Series: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0003509
EISBN: 978-1-62708-180-1
... that, although the wrought form of a metal or alloy is resistant to corrosion in a particular environment, the welded counterpart is not. Conversely, there are also many instances in which the weld exhibits corrosion resistance superior to that of the unwelded base metal. There also are times when the weld...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.pulp.c9001567
EISBN: 978-1-62708-230-3
... resistance welding. Cracks initiated at the inside surface of the welded areas and penetrated through the wall thickness. In several locations, the weld fractured and the plates separated with significant spring back, indicative of high residual stresses attributed to fabrication and weld procedures...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.modes.c0046371
EISBN: 978-1-62708-234-1
.... The bearing had not seized, and there was no evidence of heat discoloration in the galled areas. The inner cone, made of modified 4720 steel and carburized for wear resistance, rode on an AISI type 630 (17-4 PH) stainless steel spacer. Consequently, it was desirable to determine whether the galled spots...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.chem.c0091617
EISBN: 978-1-62708-220-4
... must have dropped below the dewpoint at some time. It is also possible that the absence of insulation at the flange caused a cool spot at which condensation could occur. The outlet piping failed in the area of the flange-to-cone weld by SCC as the result of aqueous chlorides; the chlorides were...
Series: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0001820
EISBN: 978-1-62708-180-1
... Miscellaneous causes Secondary loads Weldments to pipe surface Wrinkle bends Internal combustion Sabotage Longitudinal weld defects High-hardness region (b) (a) Electric flash welding, electric-resistance welding, or electric-induction welding without the addition...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.modes.c9001632
EISBN: 978-1-62708-234-1
... temperature cycles calculated to be from 400 to 30 deg C (752 to 86 deg F). The window was activated to >200 Sv/h. It was determined through analysis using remote handling techniques and hot cells that the crack initiated near a spot weld used to affix thermocouples to the window surface. In addition...
Series: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0003570
EISBN: 978-1-62708-180-1
... and fabricability. In principle, however, inexpensive base materials such as carbon-manganese steels can be clad with highly erosion-resistant alloys by fusion welding ( Ref 18 ) or explosive bonding ( Ref 19 ) to protect regions subject to liquid impact. In particular, the effectiveness of cobalt-containing weld...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.process.c9001641
EISBN: 978-1-62708-235-8
... volume is shrinkage porosity. Shrinkage porosity generally has characteristic dendritic features that are clearly visible, as shown in Fig. 2 and 3 . The shrinkage porosity shown in Fig. 2 and 3 is not from a die casting but from a resistance weld in a steel assembly. Shrinkage porosity in die...
Series: ASM Failure Analysis Case Histories
Volume: 1
Publisher: ASM International
Published: 01 December 1992
DOI: 10.31399/asm.fach.v01.c9001124
EISBN: 978-1-62708-214-3
...Abstract Abstract Several wires in aluminum conductor cables fractured within 5 to 8 years of, service in Alaskan tundra. The cables were comprised of 19-wire strands; the wires were aluminum alloy 6201-T81. Visual and metallographic examinations of the cold-upset pressure weld joints...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.steel.c9001714
EISBN: 978-1-62708-232-7
..., the pit is semispherical and crater-like form. If distance between the pits is small, the pits will coalesce. Figure 2 shows condition of the J-2 joint. The welding protrusion, shown as white band, is located among both dark bands. As it can be seen in Figure 2 , some black spots, indicating metal...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.steel.c9001598
EISBN: 978-1-62708-232-7
... 20 wt.% rhodium alloy. The vessel consisted of a 12.7 cm (5 in.) diameter cylinder and a conical section, nominal wall thickness 2.03 mm (0.080 in.). A 23.6 mm (6 in.) long drain tube, nominal 6.60 mm (0.260 in.) OD and 0.762 mm (0.030 in.) wall thickness, was welded to the conical section ( Fig. 1...
Series: ASM Failure Analysis Case Histories
Volume: 3
Publisher: ASM International
Published: 01 December 2019
DOI: 10.31399/asm.fach.v03.c9001765
EISBN: 978-1-62708-241-9
...Abstract Abstract This paper describes the investigation of a corrosion failure of bottom plates on an aboveground tank used for the storage of potable water. The tank was internally inspected for the first time after six years of service. Paint blisters and rust spots were observed...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.modes.c9001163
EISBN: 978-1-62708-234-1
... a welded joint by pickling is not possible 4 . Since the coherent fine oxide film, necessary for the corrosion resistance of the alloy, can only form at smooth surfaces, no shot with sharp edges may be used that might give a too rough surface. From the operating point of view, care must be taken to make...