Abstract
An incremental and thermal electro-mechanical coupled finite element model has been presented in this study for predicting spot nugget size, gap between workpieces, and thermal expansion displacement during spot welding process. Approximate temperature dependent material properties, including physical and mechanical properties, have been considered. The spot nugget shape and the thermal expansion displacement were obtained by simulation. The solutions showed that the displacement of workpieces was directly related to the quality of solder joints and can be as a monitoring parameter of spot weld quality. These calculations provide a theoretical reference for nugget quality monitoring and forecasting by electrode expansion displacements.
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