Effect of Double-Pulse Strategy on the Expulsion Formation and Peak Loads During Resistance Spot Welding of Dissimilar Thickness Ultra - High Strength MS1500 and Mild DD11 Steels

Year 2025, Volume: 12 Issue: 1, 51 - 58, 25.03.2025

Mehmet Okan Görtan

https://doi.org/10.17350/HJSE19030000351

Abstract

Resistance spot welding (RSW) is widely utilized in the automotive industry due to its high efficiency, flexibility, and compatibility with automation. These advantages make it a preferred method for joining advanced high-strength steels, enabling lightweight designs without compromising structural integrity. This study explores the mechanical properties of resistance spot-welded joints between ultra-high-strength MS1500 steel and hot-rolled DD11 steel, with a focus on single-pulse and double-pulse welding strategies. The effects of varying current levels were evaluated in terms of tensile-shear strength, failure energy, nugget diameter, hardness distribution, and microstructural transformations. In single-pulse welding, expulsion was observed at a current of 8.6 kA, limiting joint performance. Conversely, the double-pulse welding strategy provided enhanced control, yielding superior results. Optimal performance was achieved at a second welding current of 8.4 kA, with a tensile-shear strength increase of 11.6% and a fracture energy enhancement of 32.2% compared to single-pulse welding. Beyond 8.6 kA, expulsion caused inconsistencies in mechanical properties, highlighting the importance of current optimization in welding strategies. The findings demonstrate the effectiveness of the double-pulse welding strategy in improving the strength and quality of resistance spot-welded joints.

Keywords

Resistance spot welding, Ultra-high strength steel, Double-pulse welding, Expulsion, Mechanical strength

Supporting Institution

TÜBİTAK

Project Number

5190043

Thanks

The authors wish to thank the Turkish Research Council (TÜBİTAK) for financially supporting the project 5190043.

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