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Study on non-contact measurement method of resistance spot weld nugget diameter using laser ultrasonic technique

Nomura, Kazufumi 大阪大学

2023.12.01

概要

Welding is an essential technology in manufacturing, and there are
demands for higher quality and efficiency in various applications.
Resistance spot welding, which is widely used for joining thin plates,
mainly in the automotive industry, can instantaneously join two or more
plates by the resistance heating of the metal and is in high demand
owing to its high productivity and high-work efficiency. However,
several cases of destruction originate from the welded part; hence, high
reliability is required.
For the quality control of resistance spot welding, the size and quality
of the welded part, called the nugget, are important; in addition, various
non-destructive inspections such as the hammer test are conducted.
However, because products are often mass-produced, it is difficult to
inspect all welded parts, and sampling inspection, in which a portion of
the entire lot is sampled after welding, is often adopted [1]. It is
impossible to guarantee that a sampling inspection does not contain
defective products in a lot that has passed the inspection; therefore, the
reliability of quality assurance is less than that of whole-lot inspection. ...

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Fig. 13. Relationship between nugget and estimated nugget diameters.

Fig. 14. Evaluation of the effect of irradiation position deviation in the y-axis

(Exaggerated for easier understanding).

thin plate using a laser ultrasonic system that enables remote, noncontact ultrasonic inspection. First, we adopted a mock-up of a joint

between two thin plates, and demonstrated that the distance from the

generation/detection point to the joint can be estimated by using the

diffraction of Lamb waves, which can propagate long distances within

the thin plates. Next, by measuring the actual resistance spot-welded

specimens, we demonstrated that differences in the nugget diameter of

approximately 0.5 mm can be clearly distinguished from the arrival time

of the diffraction waves. We also demonstrated that the nugget diameter

could be calculated by determining the propagation velocity of the

diffraction wave with an accuracy close to that of the measurement

using a contact-type probe.

Author statement

Kazufumi NOMURA: Conceptualization, Methodology, Software,

Investigation, Resources, Data Curation, Writing - Original Draft,

Writing - Review & Editing, Visualization, Supervision, Project

K. Nomura et al.

NDT and E International 140 (2023) 102973

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