Magnetic fluid dynamic behaviors during resistance spot welding have important influences on weld nugget formation. In this paper, a coupled multiphysics finite element model, which realizes the coupling of mass conservation, momentum conservation, energy conservation, and the Maxwell system of equations, is proposed to systematically investigate the fluid flow and heat transfer behaviors in a spot weld nugget. It is found that the flow field in the spot weld nugget evolves through five consecutive stages: incubation, fluctuation, rapid growth, rapid attenuation, and termination. Molten metal in the nugget makes regular rotational flow in four symmetrical loops, which changes the temperature gradient in weld nugget during heating and holding, and also yields significant effects on the shape and thickness of weld nugget.

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Currently, the use of advanced high strength steels (AHSSs) is the most cost effective means of reducing vehicle body weight and maintaining structural integrity at the same time. However, AHSSs present a big challenge to the traditional resistance spot welding (RSW) widely applied in automotive industries because the rapid heating and cooling procedures during RSW produce hardened weld microstructures, which lower the ductility and fatigue properties of welded joints and raise the probability of interfacial failure under external loads. Changing process parameters or post-weld heat treatment may reduce the weld brittleness, but those traditional quality control methods also increase energy consumption and prolong cycle time. In recent years, a magnetically assisted RSW (MA-RSW) method was proposed, in which an externally applied magnetic field would interact with the conduction current to produce a Lorentz force that would affect weld nugget formation. This paper is a review of an experimental MA-RSW platform, the mode of the external magnetic field and the mechanism that controls nugget shape, weld microstructures and joint performance. The advantages of the MA-RSW method in improving the weldability of AHSSs are given, a recent application of the MA-RSW process to light metals is described and the outlook for the MA-RSW process is presented.

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A ring-shaped permanent magnet is applied in resistance spot welding to improve the weld quality of austenitic stainless steel. Under the action of an external magnetic field, the profile of the weld nugget became peanut-shaped instead of ellipsoidal. The crystal orientation near the faying surface was less directional, and equiaxed grains were formed in weld nugget centre. Moreover, the shrinkage cavities tendency in traditional resistance spot welds was reduced. The relatively slow cooling speed could cause element segregation and thus change solidification mode and significantly affect weld microstructures. The mechanical performance of the welds was finally improved by the applied external magnetic field in terms of microhardness and lap-shear strength.

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Traditional spot welds and magnetically assisted spot welds were made in 2.25 mm thick galvanised dual-phase steel, and the weld microstructures were compared. The magnetically assisted weld nugget had a 'dog bone' shape, and it had an increased diameter, which indicates a larger load-bearing area that will improve mechanical performance. The fusion zone of the magnetically assisted welds had a finer and less-directional grain structure than the conventional welds, which would improve weld strength, plastic strains, and ductility. Both types of welds contained an unusual soft zone very close to the fusion zone that is thought to be an integral part of the fusion zone. The soft zone of the magnetically assisted welds was wider than the conventional welds.