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Nondestructive Testing of Spot Welds using an Ultrasonic Resistance

This paper presents a current development of NDT for quality control of resistance spot welds using an Ultrasonic Resistance Spot Weld Analyzer (RSWA). One of the most difficult issues that automotive manufacturers face is the detection of stick welds. This has been significantly improved through advanced algorithms with a high degree of accuracy through Advanced Secondary Echo Detection Algorithms that are implemented in its second generation RSWA F-1 Model. The first generation RSWA with its original algorithm was based on detecting the amplitude of internal reflection between welded metal plates. This amplitude was compared to the amplitude of the reflection from the surface of the metal to compensate for various surface conditions and the resulting C-scan image is built based on the obtained numbers. In practical implementation, certain types of stick welds could not be readily detected using this approach

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