v
TABLE OF CONTENT
Abstrak
i Abstract
ii Dedication
iii Acknowledgement
iv Table of Content
v List of Tables
ix List of Figures
x List of Abbreviations
xii
1. INTRODUCTION
1.1 Introduction
1 1.2
Problem Statement 2
1.3 Objective
3 1.4 Scope of Project
3 1.5
Gantt chart 8
2. LITERATURE REVIEW
2.1 Introduction
4 2.2
Resistance Welding 6
2.2.1 Types of Resistance Welds 6
2.2.1.1 Lap Welding 6
2.2.2 Resistance Welding Processes 8
2.2.2.1 Spot Welds 8
2.2.3 Weld Inspection 11
2.2.4 Spot Welding Parameter 12
2.2.4.1 Current 12
2.2.4.2 Pressure 12
vi
2.2.4.3 Time 13
2.3 6061 Aluminum Alloy
13 2.3.1 Suitability of Aluminum and its Alloys for Spot Welding
14 2.3.2 Comparison of Physical Properties of Aluminum and Unalloyed Steel
16 2.3.3 Resistances during Spot Welding of Steel and Aluminium
17 2.4 Mechanical Properties
18 2.4.1 Tensile Test
18 2.4.2 Stress Strain Curves
19 2.4.3 Basic Calculation
19 2.4.4 Ductility
20 2.5 Hardness Test
22 2.5.1 Brinell Hardness Test
22 2.5.2 Rockwell Hardness Test
23 2.6
Impact Test 23
2.7 Toughness 24
2.8 Weldment Microstructure
24 2.9
Factors Influencing the Life of Electrodes 26
2.9.1 Influence of Storage Time on Life of Electrodes 26
2.10 The Process of Resistance Spot Welding 28
2.10.1 Current-Force Diagram For Spot Welding Aluminium 28
2.10.2 Recommended Values For Spot Welding With Direct Current 29
2.10.3 Example Of A Field Of Suitable Welding Parameters 30
2.10.4 Effect of Weld Spot Diameter on the Shear Strength 31
2.10.5 Correlations between Surface Pretreatment, Weld Strength and Electrode Life
31
3. METHODOLOGY
3.1 Introduction 33
3.2 Process Flow Chart
33 3.3
Experimental 35
vii
3.4 Materials preparation
36 3.5
Equipment preparation 36
3.6 Specimens Preparation
39 3.6.1 Tensile Test Specimen
39 3.6.2 Hardness Test Specimen
40 3.7
Experimentation 41
3.7.1 Microstructure Measurement 41
3.7.2 Optical Microscope Measurement 41
3.7.3 Hardness Test Measurement 42
3.7.4 Tensile Test Measurement 43
4. RESULT AND DISCUSSION
4.1 Introduction
45 4.2
Microstructure Result 46
4.2.1 Microstructure for 1.0mm and 1.5mm thickness 46
4.3 Optical Measurement Result
47 4.3.1 Relationship between 1.0mm and 1.5mm Thickness and Optical
Measurement 48
4.4 Hardness Result
50 4.4.1 Hardness of 1.5mm thickness
51 4.4.2 Hardness of 1.0mm thickness
52 4.5
Tensile Test Result 53
4.5.1 Result of 1.0 mm thickness 54
4.5.1.2 Stress versus Strain Analysis for 1.0mm thickness 55
4.5.2 Result of 1.5 mm thickness 56
4.5.1.2 Stress versus Strain Analysis for 1.5mm thickness 57
4.5.3 Different of maximum forces for 1.0mm and 1.5mm thickness 58
viii
5. CONCLUSION AND RECOMMENDATION
