Abstract
In this paper, with the ANSYS, a 2D axisymmetric coupled thermo-electro-mechanical model was developed to analyze the spot welding process（RSW） of zinc coated steels with copper strips as an insert material between electrode and workpiece. A transient temperature field obtained from a prior performed thermal–electrical simulation of RSW process is applied as nodal load on the model to simulate the stress distribution. The temperature and stress distributions in such a welding process were obtained and compared with a conventional resistance spot welding process. The results show that using the same welding process parameters, the maximum transient temperature at the electrode surface is lower than the conventional RSW process due to the use of copper strips, which helps to extend electrode lifetime. In addition, the presence of inserted copper strip increased the resistance of welding system, thus generated much more heat to form larger nugget.
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