Simulation analysis of ultrasonic detection for resistance spot welding based on COMSOL Multiphysics

The simulated calculation is carried out on the ultrasonic detection process for stainless steel resistance spot welding by the finite element technology. It reveals the ultrasonic propagation characteristics and regularity in the inner of the spot welds, and provides a theoretical basis for selecting the Am as a characteristic parameter to represent the fusion state of the spot weld in the actual ultrasonic detection. Then the ultrasonic detection of spot welds with the presence of the porosity defect which easily appears is simulated, and the effect of the porosity on the ultrasonic propagation characteristics is studied. It is found that the ultrasonic reflection and transmission occur at the porosity defect, and finally the correctness and validity of the simulation and the model are verified by the experimental method.

[1]  Hamed Sabet,et al.  Investigation on the resistance spot-welded austenitic/ferritic stainless steel , 2014 .

[2]  Ch. Ratnam,et al.  Ultrasonic based structural damage detection using combined finite element and model Lamb wave propagation parameters in composite materials , 2013 .

[3]  Ratna Babu Chinnam,et al.  Online qualitative nugget classification by using a linear vector quantization neural network for resistance spot welding , 2008 .

[4]  Li Han,et al.  Progress in NDT of resistance spot welding of aluminium using ultrasonic C-scan , 2012 .

[5]  T. Belytschko,et al.  Element‐free Galerkin methods , 1994 .

[6]  Luquan Ren,et al.  Defect intelligent identification in resistance spot welding ultrasonic detection based on wavelet packet and neural network , 2017 .

[7]  Primož Podržaj,et al.  Resistance spot welding control based on fuzzy logic , 2011 .

[8]  Yi Luo,et al.  Regression modeling and process analysis of resistance spot welding on galvanized steel sheet , 2009 .

[9]  M. Fujita,et al.  Ultrasonic Evaluation of Spot Welding Nugget Diameter with a Line-Focused Probe , 2009 .

[10]  W. Ke,et al.  3D finite element simulations of an air-coupled ultrasonic NDT system , 2009 .

[11]  Yashar Javadi,et al.  Using finite element and ultrasonic method to evaluate welding longitudinal residual stress through the thickness in austenitic stainless steel plates , 2013 .

[12]  Min Jou,et al.  Real time monitoring weld quality of resistance spot welding for the fabrication of sheet metal assemblies , 2003 .

[13]  J. Degrieck,et al.  Ultrasonic polar scans: numerical simulation on generally anisotropic media. , 2006, Ultrasonics.

[14]  Lin Hua,et al.  Research on the Detection Model and Method for Evaluating Spot Welding Quality Based on Ultrasonic A-Scan Analysis , 2016 .

[15]  Krishnan Balasubramaniam,et al.  Simulation of the TOFD technique using the finite element method , 2007 .

[16]  Li Yang,et al.  Nondestructive In-situ Permittivity Measurement of Liquid Within a Bottle Using an Open-Ended Microwave Waveguide , 2016 .

[17]  Dawei Zhao,et al.  Quality monitoring based on dynamic resistance and principal component analysis in small scale resistance spot welding process , 2016 .

[18]  Fujun Wang,et al.  A new method for nondestructive quality evaluation of the resistance spot welding based on the radar chart method and the decision tree classifier , 2015 .

[20]  A.M. Cheitov,et al.  Acoustic Microscopy of Internal Structure of Resistance Spot Welds , 2007, IEEE Transactions on Ultrasonics, Ferroelectrics and Frequency Control.

[21]  Jürgen Biber,et al.  Quality evaluation in resistance spot welding by analysing the weld fingerprint on metal bands by computer vision , 2007 .