Investigations into analysis and modeling of resistance spot welding process

The resistance spot welding involves electric, thermal and mechanical phenomenon. In this paper, the aspects of process analysis and modeling are discussed. The mechanical properties, electrical properties and thermal properties of the boundary elements vary with the contact state, and can have various values from the worksheets and electrodes. The nugget dimensions and its development process predicted by numerical modeling match well with the experimental results. In the process, the temperature, electrode pressure, stress and strains are difficult to predict. It is observed that during the welding cycles there is compressive stress in the contact area of weld surfaces, which is supportive for good metallurgical structure, forming a thick weld nugget. Further, the high contact stress at the edge of the electrode will eventually lead to permanent deformation in the surrounding area during cyclic loading. The methods presented in this paper provide an estimate of the quality, form and contour of the weld nuggets with variations in the processing conditions.