A comparative study of constant current control and adaptive control on electrode life time for resistance spot welding of galvanized steels

With using adaptive control of the resistance spot welding machine, the advantage on electrode life time for galvanized steels has been addressed. This study was aimed to evaluate the electrode life time of galvanized steels with applying the constant current control and the adaptive control resistance spot welding process for a comparison purpose. The growth in diameter of electrode face was similar for both the constant current and the adaptive control up to 2000 welds. The button diameter was decreased with weld numbers, however, sudden increase in button diameter with use of the adaptive control after 1500 welds was observed. The peak load was continuously decreased with increasing number of welds for both the constant current and the adaptive control. The current compensation during a weld was observed with using the adaptive control after 1800 welds since the -peak on dynamic resistance curve was detected at later weld time. The current compensation with adaptive control during resistance spot welding enhanced the nugget diameter at the faying interface of steel sheets and improved the penetration to thinner steel sheet.