Finite element modeling of resistance spot welding and nugget properties prediction

2009 ◽  
Author(s):  
Wenlong Mei
Keyword(s):  
Finite Element ◽  
Finite Element Modeling ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Element Modeling ◽  
Resistance Spot

scholarly journals Experimental and numerical analysis of shunting effect in resistance spot welding of Al2219 sheets

2016 ◽  
Vol 64 (2) ◽  
pp. 425-434 ◽  
Author(s):  
M. Jafari Vardanjani ◽  
A. Araee ◽  
J. Senkara ◽  
J. Jakubowski ◽  
J. Godek
Keyword(s):  
Finite Element ◽  
Heat Affected Zone ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Numerical Solutions ◽  
Potential Temperature ◽  
Model Verification ◽  
Spot Welds ◽  
Resistance Spot ◽  
Shunting Effect

Abstract Few aspects of shunting effect have been studied so far. Shunting effect in resistance spot welding (RSW) occurs when the electrical current passes through the previous spot welds. Value of this current depends mostly on distance, number, and size of previous spot welds. This will cause some dimensional and metallurgical changes in welding nugget as well as heat affected zone (HAZ). In this study, shunting effect of RSW is considered by finite element method (FEM) and the results are compared to experiments performed on aluminum alloy 2219. Weld spacing together with welding current and time are considered to discover the effect of shunting current in the final quality of nugget. A three factor experiment design has been performed to find the significance of factors and interactive effects, as well as finite element model verification. Electrothermal and mechanical interactions are considered in the FEM. Experimental and numerical solutions have yielded similar results in terms of welding nugget properties. Asymmetry in electrical potential, temperature, stress distribution and geometry of shunted nugget is predicted and verified directly or indirectly. Intense effect of shunting current on nugget height, asymmetric growth of heat affected zone (HAZ) toward previous welding nugget, as well as concentration of alloying elements along grain boundaries are also discovered.

Consideration of micro-finite element model for multiscale resistance spot welding analysis

2017 ◽  
Vol 2017.30 (0) ◽  
pp. 292
Author(s):  
Hiroyuki Kuramae ◽  
Tomoya Niho ◽  
Hirochika Aramaki ◽  
Kengo Oya ◽  
Tomoyoshi Horie
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Element Model ◽  
Resistance Spot

scholarly journals ANALYSIS OF SPOT WELDING ELECTRODE

2013 ◽  
pp. 263-268
Author(s):  
RAJANARENDER REDDY PINGILI
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
The Other ◽  
Element Analysis ◽  
Resistance Spot ◽  
Electrode Shape ◽  
The Finite Element Analysis ◽  
Welding Electrode

Electric resistance spot welding has been extensively used for many years in the automotive and aerospace industry for joining body sheet components. Compared to other welding processes such as arc welding process, resistance spot welding is fast, easily automated and easily maintained. Accurate thermal analysis of spot welding electrode could permit critical design parameters to be identified for improved electrode life. It is a complex process where coupled interactions exist between electrical, thermal and mechanical phenomena. On the other hand, finite element method (FEM), which can deal with nonlinear behaviors and complex boundary conditions, provides a powerful tool for studying these interactions and has become the most important method for the analysis of resistance spot welding. In this study, a 2-D finite element model has been developed to predict the transient thermal behavior of spot welding electrodes. The model included heat transfer analysis, electrical field analysis and phase change during melting or solidification and temperature dependant material properties, and also their inter-dependence. The contacts at faying surface and at electrode – work interface, with temperature dependant contact resistances were modeled. Three types of electrode shapes – flat, pointed and dome nose were analyzed. Temperature distribution on each electrode shape was obtained from the finite element analysis. Maximum temperature of 2876 ºC was observed in dome nose electrode in 0.2 seconds of welding time. Dome nose electrode requires a minimum weld time of all the other electrode shapes to get the required nugget size, resulting in the least power consumption. Nugget size was predicted for each electrode shape. Experimental results obtained were in good agreement with the finite element analysis results.

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