Abstract
Resistance spot welding (RSW) is a common joining technique in the production of car bodies in white for example, because of its high degree of automation, its short process time, and its reliability. While different steel grades and even dissimilar metals can be joined with this method, the current paper focuses on similar joints of galvanized advanced high strength steel (AHSS), namely dual phase steel with a yield strength of 1200 MPa and high ductility (DP1200HD). This material offers potential for light-weight design. The current work presents a multi-physical finite element (FE) model of the RSW process which gives insights into the local loading and material state, and which forms the basis for future investigations of the local risk of liquid metal assisted cracking and the effect of different process parameters on this risk. The model covers the evolution of the electrical, thermal, mechanical, and metallurgical fields during the complete spot welding process. Phase transformations like base material to austenite and further to steel melt during heating and all relevant transformations while cooling are considered. The model was fully parametrized based on lab scale material testing, accompanying model-based parameter determination, and literature data, and was validated against a large variety of optically inspected burst opened spot welds and micrographs of the welds.
Highlights
Well fabricated spot welds are of great interest especially in the automotive industry, because typically up to 5000 spot welds are set per vehicle [1,2]
It is important to point out that the above-described model calibration procedure was carried out for a X-calliper, whereas the results provided in Figure 6 were obtained with equal welding parameters but on a different Resistance spot welding (RSW) rig with a C-calliper
RSW processes collected in collected lab scale material tests
Summary
Well fabricated spot welds are of great interest especially in the automotive industry, because typically up to 5000 spot welds are set per vehicle [1,2]. An in-depth knowledge of the process is necessary to allow for designing welding systems and processes for reproducible and reliable welding joints while keeping the welding times short. The use of advanced high strength steels (AHSS) opens a big opportunity for light weight design of car bodies, which supports fulfilling the demands on resource economy and environmentally friendly transport. The high-ductility grades, which allow for better formability and increased safety, are especially gaining importance [3]. To increase the corrosion performance of these steels they are typically galvanized with zinc layers of about 7 μm thickness on both sides of the steel sheet.
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