Monitoring resistance spot nugget size by electrode displacement

A high-speed video imaging system was employed to directly measure the electrode displacement of the small scale resistance spot welding (SSRSW) process. This measurement technique was chosen because it eliminates a number of potential error sources inherent in other electrode displacement measuring techniques. Careful observation of the heating and cooling portions of the electrode displacement curves revealed that each is comprised of two identifiable segments. Distinct high-velocity segments of the displacement curves were thought to correspond to solid-liquid phase transitions in the weld nugget, while lower-velocity portions corresponded to thermal expansion or contraction of solid material. It was found that the magnitudes of the high speed portions of the electrode displacement were more closely correlated with the weld nugget thickness than was the overall magnitude of the electrode displacement. Furthermore, all measures of electrode displacement were more closely correlated to weld nugget thickness than to nugget diameter.