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Abstract
In the present work, double foil butt resistance seam welding in an automotive floor component has been investigated. The possibility of reducing foil from the existing configuration is evaluated. Mechanical properties of the single and double foil weld configuration are compared using tensile tests. The fractography of failed location is analyzed, and the force distribution in base metal and welded specimen is derived analytically to explain the observations in tensile tests. The microstructure and hardness profile of both the weld configurations and their influence on the mechanical properties are analyzed. The weld defect is analyzed using ultrasonic inspection technique. Based on the evaluation of metallurgical characterization and mechanical properties evaluation, the number of foils in an automotive floor component has been optimized. Cost savings of around 30% in the welding process is achieved by foil optimization.
Notes
Current affiliation for G. Balachandran: Kalyani Carpenter Special Steels Ltd., Pune, India.