Analytical solution of temperature distribution in resistance spot welding

Abstract

In this study, an analytical model based on integral transformations was developed to predict nugget diameters in resistance spot welding of 1.5 mm thick 5083-O aluminum alloy sheets. Welding time was fixed at six cycles. However, welding current and electrode pressure were changed; experiments were carried out for both situations. First, the effect of contact resistance on nugget diameters was studied. During the welding process, three electrode forces were selected at 2500, 3000, and 3500 N, and the welding current was fixed at 20 kA. Second, the effect of welding current on the nugget diameter was investigated. In the investigation, the electrode force was fixed at 3000 N, and the welding current was varied at 20, 25, and 30 kA. To improve accuracy, a correction factor to thermal expansion was considered. Finally, the effect of welding time on thermal history was investigated theoretically.