Proof of Concept: Real-Time Integrated Weld Analyzer in Aluminum Spot Welds

Use of aluminum alloys in the automotive industry comes with huge manufacturing challenges such as instability of spot welding processes. To overcome this challenge, frequent selective quality tests are performed in industry usually by destructive means, which are labour intensive and costly due to its nature. Non-destructive testing (NDT) of aluminum spot welds can decrease these costs. This proposed spot welding NDT method will incorporate an ultrasonic probe in the welding electrode, which is fully automated and each spot weld tested at the moment of manufacture.