Resistance Spot Welding of Aluminum Alloy to Steel with Transition Material - Part II: Finite Element Analyses of Nugget Growth

Journal Article · Thu Jul 01 04:00:00 EDT 2004 · Welding Journal

OSTI ID:15020890

Sun, Xin; Khaleel, Mohammad A

This paper summarizes work on finite element modeling of nugget growth for resistance spot welding of aluminum alloy to steel. It is a sequel to a previous paper on experimental studies of resistance spot welding of aluminum to steel using a transition material. Since aluminum alloys and steel cannot be readily fusion welded together due to their drastically different thermal physical properties, a cold-rolled clad material was introduced as a transition to aid the resistance welding process. Coupled electrical-thermal-mechanical finite element analyses were performed to simulate the nugget growth and heat generation patterns during the welding process. The predicted nugget growth results were compared to the experimental weld cross sections. Reasonable comparisons of nugget size were achieved. The finite element simulation procedures were also used in the electrode selection state to help reduce weld expulsion and improve weld quality.

• Research Organization: Pacific Northwest National Laboratory (PNNL), Richland, WA (US)
• Sponsoring Organization: USDOE
• DOE Contract Number: AC05-76RL01830
• OSTI ID: 15020890
• Report Number(s): PNNL-SA-42133; VT0502010
• Journal Information: Welding Journal, Journal Name: Welding Journal Journal Issue: 7 Vol. 83
• Country of Publication: United States
• Language: English

Related Subjects

36 MATERIALS SCIENCE
ALLOYS
ALUMINIUM
CROSS SECTIONS
ELECTRODES
PHYSICAL PROPERTIES
RESISTANCE WELDING
SIMULATION
STEELS
WELDING
aluminum alloy
aluminum-clad steel
dissimilar metals joining
finite element analysis
nugget growth
resistance spot welding
transition material
welding process simulation