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Part of: Synthesis digital library of engineering and computer science.

1. Introduction to resistance spot welding --

2. Resistance spot welding process physics and fundamentals -- 2.1 Mechanism of heat generation and nugget growth -- 2.2 Effect of electrode force on contact resistance -- 2.3 Current range and lobe curves -- 2.4 Determination of spot welding parameters for production -- 2.5 Dynamic resistance -- 2.6 Heat balance --

3. Resistance spot welding machines, electrodes, and tooling -- 3.1 Machine types -- 3.2 Power supplies -- 3.3 Electrode materials -- 3.4 Electrode geometries --

4. Resistance spot welding of modern steels -- 4.1 Introduction to automotive steels -- 4.2 Conventional steels -- 4.3 Welding of conventional uncoated steels -- 4.4 Advanced high-strength steels -- 4.4.1 Transformation-induced plasticity (TRIP) steels -- 4.4.2 Dual phase (DP) steels -- 4.4.3 Complex phase (CP) steels -- 4.4.4 Martensitic (MS) steels -- 4.4.5 Twinning-induced plasticity (TWIP) steels -- 4.4.6 Hot-formed (HF) steels -- 4.4.7 Ferritic-bainitic (FB) steels -- 4.5 Welding of advanced high-strength steels -- 4.5.1 Spot welding parameters -- 4.5.2 Carbon equivalence and spot weld failure modes --

5. Resistance spot welding of coated advanced high-strength steels -- 5.1 Overview of coated steels -- 5.2 Welding of zinc-coated steels -- 5.3 Welding of coated HF (boron) steels --

6. Resistance spot welding of aluminum -- 6.1 Overview of aluminum -- 6.1.1 Dynamic resistance curves -- 6.1.2 Plastic range -- 6.1.3 Thermal and electrical conductivity -- 6.1.4 Coefficient of thermal expansion -- 6.1.5 Oxide layer -- 6.2 Spot welding of aluminum -- 6.3 Novel approaches to spot welding aluminum -- 6.3.1 GM's multi-ringed domed electrode -- 6.3.2 Fronius DeltaSpot process -- 6.4 Spot welding aluminum to steel --

7. Design and weld strength considerations for resistance spot welding -- 7.1 Spot weld mechanical property considerations -- 7.2 Multiple sheet stack-ups -- 7.3 One-sided welding -- 7.4 Weld bonding --

8. Resistance spot welding quality, testing, monitoring, and control -- 8.1 Discontinuities and defects -- 8.2 Destructive testing of spot welds -- 8.2.1 Peel and chisel testing -- 8.2.2 Mechanical testing -- 8.3 Nondestructive evaluation (NDE) and monitoring techniques -- 8.4 Computational modeling of resistance spot welding --

9. Resistance spot welding production issues -- 9.1 Electrode wear -- 9.1.1 Choice of electrode geometry for long life -- 9.1.2 Managing electrode wear -- 9.2 Electrode cooling -- 9.3 Electrode alignment and part fit-up -- 9.4 Pneumatic vs. electric servo guns --

10. Overview of resistance spot welding codes and standards -- 10.1 AWS C1.1 -- 10.2 AWS D8.1 -- 10.3 AWS D8.9 -- 10.4 ISO standards -- 10.5 RWMA -- Author biographies.

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The early chapters of this book provide thorough coverage of resistance spot welding fundamentals and principles. Topics covered include lobe and current range curves, contact resistance vs. electrode force, dynamic resistance, heat balance, nugget growth, etc. Equipment issues such as machine types, power supplies, and electrodes are addressed. Subsequent chapters focus on specific spot welding challenges to modern automotive manufacturing. Approaches to welding modern materials including advanced high-strength steels, coated steels, and aluminum alloys are covered in much detail. The final chapters focus on many common production and quality control issues, such as electrode wear, monitoring and testing, computational modeling, and welding codes. The overall goal of the book is to provide a comprehensive resource for automotive engineers and technicians who work with modern spot welding equipment and automotive materials.

Also available in print.

Title from PDF title page (viewed on October 3, 2017).