An axisymmetric finite element program was developed to simulate the process of resistance spot welding. The effect of welding condition on the temperature distribution in the electrode and the determination of welding conditions on galvanized steel sheet were studied. A calibration method was used to measure the contact resistance in welding process. A method of active and deactive element was also employed to simulate the effect of molten zinc on galvanized steel sheet on the welding process. The results show that the model can simulate the spot welding process very well. The welding conditions have a significant effect on the temperature distribution of the electrode. The lowest temperature of electrode can be reached when using standard welding condition. The molten zinc on galvanized sheet during welding can give influence on the temperature distribution of the electrode in a great deal. It is very important to consider the cooling of the electrode when welding a galvanized sheet.
Journal of Shanghai Jiaotong University