Computational and Experimental Analysis of Residual Stresses in Resistance Spot Welding

Wang, L., Felicelli, S. D., Bammann, D., & Hubbard, C. R. (2009). Computational and Experimental Analysis of Residual Stresses in Resistance Spot Welding. International Conference WELDS 2009. Fort Myers, FL .

Abstract

Using the commercial welding software SYSWELD, an electro-thermo-mechanical finite element model was developed, which considers also the effect of metallurgical phase transformations. The model was employed to predict the temperature history, nugget size growth, and the residual stress field during different stages of resistance spot welding. The effects of welding parameters such as current, pressure, and weld cycles on residual stress distribution were investigated. To validate the predicted stresses neutron and X-ray diffraction residual stress mapping was used to characterize the through-thickness stresses and surface stresses in a spot welded steel joint. The origin of the residual stress distribution is discussed based on the thermal histories of the samples, and the calculated stresses are compared with measurements obtained by neutron diffraction mapping.