Numerical Simulation of Resistance Spot Welding Process

Abstract

Abstract This paper develops a model to predict the nugget development during resistance spot welding (RSW) of Al-alloys. The model employs a coupled thermal-electrical-mechanical analysis and accounts for phase change and convective transport in the weld pool. The contact area and the pressure distribution are determined from a coupled thermal ? mechanical model. The model calculates time varying interface pressure. The knowledge of interface pressure allows for accurate prediction of interfacial heat generation. Temperature-dependent thermal-electrical-mechanical properties are used. The predicted nugget shape and size agree well with experimental data. The proposed model can be applied to predict the effects of the welding parameters and the electrode shapes on the nugget development.