Prediction and Verification of Resistance Spot Welding Results of Ultra-High Strength Steels through FE Simulations
Affiliation(s)
1 Department of Production Engineering, KTH Royal Institute of Technology, Stockholm, Sweden. 2 Swerea KIMAB, Kista, Sweden.
1 Department of Production Engineering, KTH Royal Institute of Technology, Stockholm, Sweden. 2 Swerea KIMAB, Kista, Sweden.
ABSTRACT
Resistance spot welding (RSW) is the most common welding method in automotive engineering due to its low cost and high ability of automation. However, physical weldability testing is costly, time consuming and dependent of supplies of material and equipment. Finite Element (FE) simulations have been utilized to understand, verify and optimize manufacturing processes more efficiently. The present work aims to verify the capability of FE models for the RSW process by comparing simulation results to physical experiments for materials used in automotive production, with yield strengths from approximately 280 MPa to more than 1500 MPa. Previous research has mainly focused on lower strength materials. The physical weld results were assessed using destructive testing and an analysis of expulsion limits was also carried out. Extensive new determination of material data was carried out. The material data analysis was based on physical testing of material specimens, material simulation and comparison to data from literature. The study showed good agreement between simulations and physical testing. The mean absolute error of weld nugget size was 0.68 mm and the mean absolute error of expulsion limit was 1.10 kA.
Resistance spot welding (RSW) is the most common welding method in automotive engineering due to its low cost and high ability of automation. However, physical weldability testing is costly, time consuming and dependent of supplies of material and equipment. Finite Element (FE) simulations have been utilized to understand, verify and optimize manufacturing processes more efficiently. The present work aims to verify the capability of FE models for the RSW process by comparing simulation results to physical experiments for materials used in automotive production, with yield strengths from approximately 280 MPa to more than 1500 MPa. Previous research has mainly focused on lower strength materials. The physical weld results were assessed using destructive testing and an analysis of expulsion limits was also carried out. Extensive new determination of material data was carried out. The material data analysis was based on physical testing of material specimens, material simulation and comparison to data from literature. The study showed good agreement between simulations and physical testing. The mean absolute error of weld nugget size was 0.68 mm and the mean absolute error of expulsion limit was 1.10 kA.
Cite this paper
Andersson, O. and Melander, A. (2015) Prediction and Verification of Resistance Spot Welding Results of Ultra-High Strength Steels through FE Simulations. Modeling and Numerical Simulation of Material Science, 5, 26-37. doi: 10.4236/mnsms.2015.51003.
Andersson, O. and Melander, A. (2015) Prediction and Verification of Resistance Spot Welding Results of Ultra-High Strength Steels through FE Simulations. Modeling and Numerical Simulation of Material Science, 5, 26-37. doi: 10.4236/mnsms.2015.51003.
References
[1] Weber, G., Thommes, H., Gaul, H., Hahn, O. and Rethmeier, M. (2010) Resistance Spot Welding and Weldbonding of Advanced High Strength Steels. Materialwissenschaft und Werkstofftechnik, 41, 931-939. http://dx.doi.org/10.1002/mawe.201000687 [2] Archer, G. (1960) Calculations for Temperature Response in Spot Welds. Welding Journal, 39, 327-s-330-s. [3] Greenwood, J. (1961) Tempera in Spot Welding. British Welding Journal, 8, 316-322. [4] Nied, H. (1984) The Finite Element Modelling of the Resistance Spot Welding Process. Welding Journal, 63, 123s- 132s. [5] Nishiguchi, K. and Matsuyama, K. (1987) Influence of Current Wave Form on Nugget Formation Phenomena When Spot Welding Thin Steel Sheet. Welding in the World, 25, 222-244. [6] Feulvarch, E., Rogeon, P., Carr, P., Robin, V., Sibilia, G. and Bergheau, J. (2006) Resistance Spot Welding Process: Experimental and Numerical Modeling of the Weld Growth Mechanisms with Consideration of Contact Conditions. Numerical Heat Transfer Part A: Applications, 49, 345-367. http://dx.doi.org/10.1080/10407780500359760 [7] Murakawa, H., Zhang, J., Fujii, K., Wang, J. and Ryudo, M. (2000) FEM Simulation of Spot Welding Process. Transactions of JWRI, 29, 73-80. [8] Zhang, W. (2003) Design and Implementation of Software for Resistance Welding Process Simulations. SAE Technical Papers 2003-01-0978. http://dx.doi.org/10.4271/2003-01-0978 [9] Tsai, C.L., Dai, W.L., Dickinson, D.W. and Papritan, J.C. (1989) Analysis and Development of a Real-Time Control Methodology in Resistance Spot-Welding. Welding Journal, 70, 339s-351s. [10] Gupta, O. and De, A. (1998) An Improved Numerical Modeling for Resistance Spot Welding Process and Its Experi- mental Verification. Journal of Manufacturing Science and Engineering, Transactions of the ASME, 120, 246-251.
http://dx.doi.org/10.1115/1.2830120 [11] Long, X. and Khanna, S.K. (2003) Numerical Simulation of Residual Stresses in a Spot Welded Joint. Journal of Engineering Materials and Technology, 125, 222-226.
http://dx.doi.org/10.1115/1.1543968 [12] Moshayedi, H. and Sattari-Far, I. (2012) Numerical and Experimental Study of Nugget Size Growth in Resistance Spot Welding of Austenitic Stainless Steels. Journal of Materials Processing Technology, 212, 347-354.
http://dx.doi.org/10.1016/j.jmatprotec.2011.09.004 [13] Nodeh, I.R., Serajzadeh, S. and Kokabi, A.H. (2008) Simulation of Welding Residual Stresses in Resistance Spot Welding, FE Modeling and X-Ray Verification. Journal of Materials Processing Technology, 205, 60-69.
http://dx.doi.org/10.1016/j.jmatprotec.2007.11.104 [14] Shen, J., Zhang, Y., Lai, X. and Wang, P.C. (2011) Modeling of Resistance Spot Welding of Multiple Stacks of Steel Sheets. Materials and Design, 32, 550-560.
http://dx.doi.org/10.1016/j.matdes.2010.08.023 [15] Afshari, D., Sedighi, M., Karimi, M.R. and Barsoum, Z. (2013) On Residual Stresses in Resistance Spot-Welded Aluminum Alloy 6061-T6: Experimental and Numerical Analysis. Journal of Materials Engineering and Performance, 22, 3612-3619. http://dx.doi.org/10.1007/s11665-013-0657-1 [16] Dancette, S., Massardier-Jourdan, V., Fabrègue, D., Merlin, J., Dupuy, T. and Bouzekri, M. (2011) HAZ Microstructures and Local Mechanical Properties of High Strength Steels Resistance Spot Welds. ISIJ International, 51, 99-107.
http://dx.doi.org/10.2355/isijinternational.51.99 [17] Radakovic, D.J. and Tumuluru, M. (2008) Predicting Resistance Spot Weld Failure Modes in Shear Tension Tests of Advanced High-Strength Automotive Steels. Welding Journal (Miami, Florida), 87, 96-105. [18] (2008) Thermo-Calc for Windows Version 5 User’s Guide. [19] Miettinen, J., Louhenkilpi, S., Kytönen, H. and Laine, J. (2010) IDS: Thermodynamic-Kinetic-Empirical Tool for Modeling of Solidification, Microstructure and Material Properties. Mathematics and Computers in Simulation, 80, 1536-1550. http://dx.doi.org/10.1016/j.matcom.2009.11.002 [20] (2007) MATLAB Documentation. [21] Shen, J., Zhang, Y. and Lai, X. (2010) Influence of Initial Gap on Weld Expulsion in Resistance Spot Welding of Dual Phase Steel. Science and Technology of Welding and Joining, 15, 386-392.
http://dx.doi.org/10.1179/136217110X12693513264213 [22] Andersson, O. and Melander, A. (2011) Statistical Analysis of Variations in Resistance Spot Weld Nugget Sizes. IIW Annual Assembly, Chennai.
[1] Weber, G., Thommes, H., Gaul, H., Hahn, O. and Rethmeier, M. (2010) Resistance Spot Welding and Weldbonding of Advanced High Strength Steels. Materialwissenschaft und Werkstofftechnik, 41, 931-939. http://dx.doi.org/10.1002/mawe.201000687 [2] Archer, G. (1960) Calculations for Temperature Response in Spot Welds. Welding Journal, 39, 327-s-330-s. [3] Greenwood, J. (1961) Tempera in Spot Welding. British Welding Journal, 8, 316-322. [4] Nied, H. (1984) The Finite Element Modelling of the Resistance Spot Welding Process. Welding Journal, 63, 123s- 132s. [5] Nishiguchi, K. and Matsuyama, K. (1987) Influence of Current Wave Form on Nugget Formation Phenomena When Spot Welding Thin Steel Sheet. Welding in the World, 25, 222-244. [6] Feulvarch, E., Rogeon, P., Carr, P., Robin, V., Sibilia, G. and Bergheau, J. (2006) Resistance Spot Welding Process: Experimental and Numerical Modeling of the Weld Growth Mechanisms with Consideration of Contact Conditions. Numerical Heat Transfer Part A: Applications, 49, 345-367. http://dx.doi.org/10.1080/10407780500359760 [7] Murakawa, H., Zhang, J., Fujii, K., Wang, J. and Ryudo, M. (2000) FEM Simulation of Spot Welding Process. Transactions of JWRI, 29, 73-80. [8] Zhang, W. (2003) Design and Implementation of Software for Resistance Welding Process Simulations. SAE Technical Papers 2003-01-0978. http://dx.doi.org/10.4271/2003-01-0978 [9] Tsai, C.L., Dai, W.L., Dickinson, D.W. and Papritan, J.C. (1989) Analysis and Development of a Real-Time Control Methodology in Resistance Spot-Welding. Welding Journal, 70, 339s-351s. [10] Gupta, O. and De, A. (1998) An Improved Numerical Modeling for Resistance Spot Welding Process and Its Experi- mental Verification. Journal of Manufacturing Science and Engineering, Transactions of the ASME, 120, 246-251.
http://dx.doi.org/10.1115/1.2830120 [11] Long, X. and Khanna, S.K. (2003) Numerical Simulation of Residual Stresses in a Spot Welded Joint. Journal of Engineering Materials and Technology, 125, 222-226.
http://dx.doi.org/10.1115/1.1543968 [12] Moshayedi, H. and Sattari-Far, I. (2012) Numerical and Experimental Study of Nugget Size Growth in Resistance Spot Welding of Austenitic Stainless Steels. Journal of Materials Processing Technology, 212, 347-354.
http://dx.doi.org/10.1016/j.jmatprotec.2011.09.004 [13] Nodeh, I.R., Serajzadeh, S. and Kokabi, A.H. (2008) Simulation of Welding Residual Stresses in Resistance Spot Welding, FE Modeling and X-Ray Verification. Journal of Materials Processing Technology, 205, 60-69.
http://dx.doi.org/10.1016/j.jmatprotec.2007.11.104 [14] Shen, J., Zhang, Y., Lai, X. and Wang, P.C. (2011) Modeling of Resistance Spot Welding of Multiple Stacks of Steel Sheets. Materials and Design, 32, 550-560.
http://dx.doi.org/10.1016/j.matdes.2010.08.023 [15] Afshari, D., Sedighi, M., Karimi, M.R. and Barsoum, Z. (2013) On Residual Stresses in Resistance Spot-Welded Aluminum Alloy 6061-T6: Experimental and Numerical Analysis. Journal of Materials Engineering and Performance, 22, 3612-3619. http://dx.doi.org/10.1007/s11665-013-0657-1 [16] Dancette, S., Massardier-Jourdan, V., Fabrègue, D., Merlin, J., Dupuy, T. and Bouzekri, M. (2011) HAZ Microstructures and Local Mechanical Properties of High Strength Steels Resistance Spot Welds. ISIJ International, 51, 99-107.
http://dx.doi.org/10.2355/isijinternational.51.99 [17] Radakovic, D.J. and Tumuluru, M. (2008) Predicting Resistance Spot Weld Failure Modes in Shear Tension Tests of Advanced High-Strength Automotive Steels. Welding Journal (Miami, Florida), 87, 96-105. [18] (2008) Thermo-Calc for Windows Version 5 User’s Guide. [19] Miettinen, J., Louhenkilpi, S., Kytönen, H. and Laine, J. (2010) IDS: Thermodynamic-Kinetic-Empirical Tool for Modeling of Solidification, Microstructure and Material Properties. Mathematics and Computers in Simulation, 80, 1536-1550. http://dx.doi.org/10.1016/j.matcom.2009.11.002 [20] (2007) MATLAB Documentation. [21] Shen, J., Zhang, Y. and Lai, X. (2010) Influence of Initial Gap on Weld Expulsion in Resistance Spot Welding of Dual Phase Steel. Science and Technology of Welding and Joining, 15, 386-392.
http://dx.doi.org/10.1179/136217110X12693513264213 [22] Andersson, O. and Melander, A. (2011) Statistical Analysis of Variations in Resistance Spot Weld Nugget Sizes. IIW Annual Assembly, Chennai.