A Novel Expulsion Control Strategy With Abnormal Condition Adaptability for Resistance Spot Welding

Abstract Welding expulsion is a common problem in the resistance spot welding (RSW) process, which severely impacts weld quality and surrounding facilities. Existing expulsion control strategies are ineffective for complex and changeable welding conditions. This article studied the growth relationship between weld nugget and corona bond under two abnormal conditions: edge proximity (EP) and initial sheet gaps (IG). It is testified that expulsion would occur when the nugget size exceeds the corona bond size under EP and IG conditions. Reducing the welding current before the expulsion time can increase the size difference between the corona bond and the weld nugget, thereby delay and even eliminate the occurrence of expulsion. In this way, a novel online expulsion control strategy, named short-time current regulation (STCR), is proposed through the expulsion moment analysis of historical weld data. The effect of the new control strategy is verified with workpieces ranging from low carbon steel to ultra-high strength steel. Experimental results showed that STCR can effectively reduce the amount of expelled metal, decrease the indentation depth, and increase the nugget diameter. The method not only works well under one specific abnormal condition but also adapts to the transition between different welding conditions. This novel expulsion control strategy can help achieve the expulsion-free RSW process in mass production without frequent manual offline optimization of welding parameters.