Author ORCID Identifier

https://orcid.org/0000-0001-9260-4503

Year of Publication

2019

Degree Name

Master of Science in Manufacturing Systems Engineering (MSMSE)

Document Type

Master's Thesis

College

Engineering

Department/School/Program

Manufacturing Systems Engineering

First Advisor

Dr. Fazleena Badurdeen

Abstract

The union of a set of materials by way of Resistance Spot Welding is designed so that once fused together, a substantial amount of intentional, external force must be applied to separate the contents. Therefore, Resistance Spot Welding is often the preferred fusion method in high-volume manufacturing processes. The result of Resistance Spot Welding however is the formation of a weld nugget which is not visible to the naked eye. Destructive and/or ultrasonic methods applied off-line must be used to determine the quality of each weld; both inefficient and expensive processes. The following research analyzes the data fed back during resistance spot weld sequences in-line and establishes a correlation between emitted characteristics and the final quality of a spot weld.

The two characteristics researched to segregate weld quality are: the electrical sin wave signature and the acoustic sin wave signature produced during the welding sequence. Both features were discovered to have a direct correlation to the final quality of a weld once cured. By measuring and comparing these characteristics at the source, an opportunity is presented to decrease time and potential defects by confirming the quality of each weld in-process and at the source.

Digital Object Identifier (DOI)

https://doi.org/10.13023/etd.2019.252

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