Computer simulation of resistance spot welding in aluminum: Part 1

Journal Article · Sun Oct 01 04:00:00 EDT 1995 · Welding Journal

OSTI ID:119020

Browne, D J ^[1]; Chandler, H W; Evans, J T; Wen, J ^[2]

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1. Alcan International, Banbury (United Kingdom)
2. Univ. of Newcastle upon Tyne (United Kingdom). Dept. of Mechanical, Materials and Manufacturing Engineering

A computer-based model of resistance spot welding with hemispherical electrode tips has been developed to include simulation of elastic-plastic mechanical deformation as well as ohmic heating and thermal conduction. The primary effect of the mechanical deformation is in its influence on the contact read and current density developed at the faying surface. The model was used to simulate spot welding in aluminum alloys. Preliminary results show the effects of variations in input current, contact resistance, applied force and position of the cooling water with respect to the electrode tip. It is shown that the value of the contact resistance has a large effect on nugget formation in the spot welding of aluminum alloys and that the applied force has a significant effect arising from its effect on the area of contact at the faying surface. The formation of a resistance spot weld in aluminum is also sensitive to the position of the cooling water-electrode interface because of the high thermal conductivity of aluminum alloys.

• OSTI ID: 119020
• Journal Information: Welding Journal, Journal Name: Welding Journal Journal Issue: 10 Vol. 74; ISSN 0043-2296; ISSN WEJUA3
• Country of Publication: United States
• Language: English

Related Subjects

36 MATERIALS SCIENCE
ALUMINIUM ALLOYS
COMPUTERIZED SIMULATION
MATHEMATICAL MODELS
RESISTANCE WELDING
THEORETICAL DATA