On-line measurement of nugget diameter in automatic resistance spot welding based on embedded ultrasound probe

The inspection of resistance spot welding (RSW) quality is crucial in the sheet metal joining industries. This paper proposes an enhanced approach for the automated real-time measurement of weld nugget diameter in welded joints, utilizing an ultrasonic probe integrated within the electrode. The ultrasonic signals received by the probe are sequentially arranged to generate consecutive ultrasonic B -scan images, which effectively capture the entire weld nugget growth and solidification process. The corresponding maximum time of flight (TOF) for the liquid nugget is extracted from the B -scan image. In the condition of qualified welding quality, a mathematic equation between maximum TOF and weld nugget diameter is established, while the opposite is alarmed. The on-line quality inspection of RSW can autonomously determine the qualification of welding quality, as well as quantitatively evaluate the weld nugget diameter in qualified weld joints. The research is applicable to various processing and manufacturing fields.