The University of Osaka · Engineering
Professor Sendong Ren's research lab specializes in advanced joining technologies for lightweight hybrid structures, with a primary focus on dissimilar material joining between aluminum alloys and carbon-fiber-reinforced plastics (CFRP). The lab develops innovative processes such as coaxial one-side resistance spot welding (COS-RSW) and employs advanced numerical modeling using in-house finite element codes (e.g., JWRIAN, JWRIAN-SPOT) to simulate multi-physics phenomena including thermal, electrical, and mechanical coupling. The integration of digital twin technology, artificial intelligence (e.g., multi-task learning-based ANN), and experimental validation enables real-time prediction and optimization of welding parameters and joint performance.
Figures are computed from collected data and may differ slightly.
Carbon fiber reinforced plastic (CFRP) is a prospective lightweight material in automobile industry. However, joining metal and CFRP is a great challenge. In the present study, an innovative process called coaxial one-side resistance spot welding (COS-RSW) is proposed to fabricate Al5052 (Al) and CFRP joints. Based upon our newly developed finite element code JWRIAN, the electric-thermal-mechanical coupled process of COS-RSW is modeled and validated with experiments. The influences of welding cu
Coaxial one-side resistance spot welding (COS-RSW) is an advanced technique for joining CFRP/metal dissimilar materials. In the present work, a three-dimensional model was developed based upon an in-house finite element code JWRIAN-SPOT to simulate the multi-physical process of the COS-RSW. The thermal cycle and joining strength of COS-RSW joints with different welding parameters were measured experimentally. The sensitivity of material properties of electrode couple and component of accumulated
Abstract In the present research, a digital twin of coaxial one-side resistance spot welding (COS-RSW) was established for the real-time prediction of transient temperature field. A three-dimensional (3D) model of COS-RSW joint was developed based on the in-house finite element (FE) code JWRIAN-SPOT. The experimental verified FE model was employed to generate the big data of temperature of COS-RSW process. Multiple dimension interpolation was applied to process database and output prediction. Th
Coaxial one-side resistance welding (COS-RSW) is an advanced joining technology for the metal-plastic hybrid structure, which has great application potential in the lightweight design of body-in-white. In the present research, the Al5052-CFRP cross-lap joints were fabricated by COS-RSW with different welding conditions. The author-developed finite element (FE) code JWRIAN-RSW was employed to reproduce the multi-physics coupled phenomena of COS-RSW and predict thermal history. The influence of we
Abstract Coaxial one-side resistance spot welding (COS-RSW) is a newly developed process for joining metals and composites. In the present study, Al5052 and carbon-fiber-reinforced plastic (CFRP) lap joints were fabricated via COS-RSW. The welding process was modeled numerically using an in-house finite element code called JWRIAN. Single-lap shear tests were performed to evaluate the joining strength. The molten zone diameter was defined and measured experimentally to verify the numerical model.
In the present research, coaxial one-side resistance spot welding was performed to join Al5052 and CFRP sheets with different welding currents. The mechanical performance of the cross-lap joint was clarified experimentally. The cross-section of the welded joint and the fracture surfaces was subjected to multi-scale characterization. The fracture behaviours and mechanisms of cross-lap joints are discussed in detail. The results showed that the thermal degradation of CFRP was detected on the cross
In the present research, laser circle welding (LCW) was proposed to join dual-phase steel (DP980) and carbon fiber-reinforced plastic (CFRP). The welding appearance, cross-section of the welded joint and fracture surfaces were subjected to multi-scale characterizations. Joining strength was evaluated by the single-lap shear test. Moreover, a numerical model was established based on the in-house finite element (FE) code JWRIAN-Hybrid to reproduce the thermal process of LCW. The results showed tha
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