A Review of Finite Element Analysis (FEA) of Resistance Spot Welding (RSW)

Abstract

Modeling RSW was studied by many researchers with considering different electrical, thermal, and mechanical phenomena such as formation of temperature field and welding nugget growth. This paper is a review of the most important efforts in the field of FEA of RSW, by investigating present finite element method (FEM) studies. After a brief introduction on FEA studies on RSW, such numerical solution methods as FEM and FDM (Finite Difference Method) are compared. Governing electrical, thermal, and mechanical equations are then discussed. A brief investigation about applicable algorithms is presented as a procedure for numerical solution. The importance of credible material properties is emphasized and predicted results in different studies are discussed. The final two parts are about recent issues in RSW FEA process and review of special cases such as multiple-sheet, single-sided welding, shunting effect, and covered models. Conclusions and suggestions about future studies are also provided.