Analysis and Modelling of Electrode Wear in Resistance Spot Welding

Anders Madsen (Invited author), Kim Pedersen (Invited author), Kasper Storgaard Friis (Invited author), Niels Bay (Invited author)

Research output: Chapter in Book/Report/Conference proceedingArticle in proceedingsResearch


A model describing electrode wear as a function of weld number, initial tip diameter, truncated cone angle, welding current and electrode force is proposed. Excellent agreement between the model and experimental results is achieved, showing that the model can describe the change in electrode tip diameter with increasing weld number at different weld settings. Furthermore a method for measuring the worn tip diameter in a fast and robust manner is developed. The method relies on a well-known technique for capturing the electrode tip area by the use of carbon imprints and a new developed image-processing program written in MatLab. Very fine agreement between the present experimental results and previously published wear data is achieved. Finally the pitted areas on the electrode tip are analyzed using MatLab and an optical 3D surface measurement device. Two types of pitting are characterized. One where a central cavity is formed and one where smaller pits are formed randomly across the electrode face. The influence of these two types of surface pits on the nugget size are investigated using the FE code SORPAS, revealing ring welds and undersized weld nuggets.
Original languageEnglish
Title of host publicationProceed. 6. seminar on Advances in Resistance Welding
Number of pages247
Publication date2010
Publication statusPublished - 2010
Event6th International Seminar on Advances in Resistance Welding - Hamburg, Germany
Duration: 22 Sep 201024 Sep 2010
Conference number: 6


Conference6th International Seminar on Advances in Resistance Welding


  • Numerical modeling
  • Ring weld
  • Pitting
  • Resistance spot welding
  • Electrode wear
  • Zinc coated steel
  • Electrode life


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