电极偏斜对高强钢电阻点焊的影响机理研究  

Research on Influence Mechanism of Electrode off Normal on Resistance Spot Welding Process of High Strength Steel

作　　者：闫德俊 夏裕俊 宁付星 饶宇中 宋强[2] 李永兵[2] Yan Dejun;Xia Yujun;Ning Fuxing;Rao Yuzhong;Song Qiang;Li Yongbing(Foshan University,Guangdong Provincial Key Laboratory of Advanced Welding Technology for Ships,Foshan 528051;School of Mechanical Engineering,Shanghai Jiao Tong University,Shanghai Key Laboratory of Digital Manufacture for Thin-walled Structures,Shanghai 200240;CSSC Huangpu Wenchong Shipbuilding Co.,Ltd.,Guangdong Provincial Key Laboratory of Advanced Welding Technology for Ships,Guangzhou 510705;Shanghai Spaceflight Manufacture Co.,Ltd.,Shanghai 201306)

机构地区：[1]佛山大学,广东省舰船先进焊接技术重点实验室,佛山528051 [2]上海交通大学,上海市复杂薄板结构数字化制造重点实验室,上海200240 [3]中船黄埔文冲船舶有限公司,广东省舰船先进焊接技术重点实验室,广州510715 [4]上海智能制造功能平台有限公司,上海201306

出　　处：《汽车工程》2025年第3期541-550,577,共11页Automotive Engineering

基　　金：中国科协青年人才托举工程项目(YESS20220612);上海市“科技创新行动计划”启明星项目(23QB1405700);广东省舰船先进焊接技术企业重点实验室基金(2023B1212070026)资助。

摘　　要：汽车车身轻量化技术的发展使高强钢广泛应用于汽车工业中,也为车身焊装制造中的电阻点焊工艺带来新的挑战。电极偏斜等常见异常工况的产生,会对焊接过程的一致性产生负面影响。本文通过对比标准工况与电极偏斜工况下的多传感信号、焊点表面形貌、熔核尺寸及接头形成过程,揭示了电极偏斜对电阻点焊过程的影响机制。结果表明,与标准工况相比,电极偏斜增加了板间界面的初始接触面积,导致板材升温减慢,电阻信号峰值后移,形核时间滞后。在焊接过程中,板间和电极-板材间界面的接触面积均增加,导致动态电阻信号减弱和产热量减小,因此熔核尺寸和电极位移信号低于标准工况。此外,沿长度方向的接触面积更大导致热输入比例更高,因此在该方向上熔核和压痕的尺寸更大。本研究可为实际生产环境中高强钢电阻点焊工艺优化和复杂工况下的点焊在线质量监控提供理论支撑。The development of lightweight car body technology has led to widespread usage of highstrength steel in automotive industry,which brings new challenges to the resistance spot welding(RSW)process in car body welding and manufacturing.The occurrence of common abnormal working conditions,such as electrode axis off normal(ON)can negatively impact the consistency of RSW process.In this paper,the influence mechanism of ON condition on spot welding process is revealed by comparing multi-sensor process signals,weld surface morphology,nugget size and joint formation process under standard and ON conditions.The results indicate that compared with the standard condition,the ON condition increases the initial contact area of the sheet-sheet interface,which leads to a slower temperature rise of sheets,a later peak in resistance signal and a delayed nucleation time.In the welding process,the contact area of sheet-sheet and electrode-sheet interface increases,which leads to the decrease of dynamic resistance signal and heat generation,so the nugget size and electrode displacement signal are smaller than the standard condition.Furthermore,the larger contact area along the length direction leads to more heat generation,ultimately resulting in a larger nugget dimension and indentation size in this particular direction.This study can provide theoretical support for the optimization of high-strength steel resistance spot welding process in actual production environment and online quality monitoring of spot welding under complex working conditions.

关 键 词：电阻点焊 高强钢 电极偏斜 影响机制 

分 类 号：TG456.7[金属学及工艺—焊接] TG441.8