Resistance Spot Welding of Steels: Modeling and Simulation

Abstract

Resistance spot welding (RSW) includes many variables that can influence the weld properties. The purpose of this study is to develop an analytical model for prediction of thermal history and weld microstructure in RSW and to find the most important process parameters that influence the weld microstructure. A one dimensional model is proposed for prediction about thermal history during cooling step of RSW process. The reliability of analytical model is evaluated by experiments and numerical simulations. The calculations reveal that the current analytical model is reliable particularly at the temperatures lower than T_m/2. Sheet surface temperature at electrode-sheet interface and sheet thickness are recognized as the most important factors affecting the cooling rate at T<T_m/2. Austenite decomposition is one of the most important transformations in steels that occurs in this temperature interval. Finally an easy to use map also is developed based upon the present analytical model for prediction of weld microstructure.<br />