42. A Thermo-Mechanical Finite-Element Analysis of Resistance Spot Welding of Dual-Phase Steel and Austenitic Stainless Steel

In this paper, a three-dimensional axisymmetric finite-element model for resistance spot welding of automotive steel materials is prepared to analyze the transient thermal and mechanical behaviors of weld pool. Thermal analysis is carried out to analyze the transient thermal properties of the process of resistance spot welding. Based on the results of the thermal analysis, a mechanical (structural) analysis is conducted to evaluate mechanical characteristics of resistance spot welding process. The thermal characteristics and temperature distribution within the body of weld metal have been validated by comparing it with the experimental work. The mechanical characteristics such as distribution of stresses and contact pressure at faying surfaces and electrode–sheet interfaces, the stress and strain distributions in weldment, and the changes during the welding process have been evaluated. The effect of welding parameters on weld strength was investigated. Results obtained through numerical modeling showed good agreement with experimental results.