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Current and heat flow at the contact surfaces of electrode and sheet materials play a vital role in joining of sheet metals by the Resistance Spot Welding (RSW) technique. Further, the contact resistances primarily depend on contact pressure and temperature during the RSW process. In this article, a 2-D axisymmetric, fully coupled electro-thermomechanical model developed in COMSOL software is used to study the effects of weld current and time on the evolution of temperatures, dynamic resistance and nugget size. Contact conductance method for contact resistances and latent heat capacity method for phase change (melting/solidification) process are used. The predicted nugget sizes are compared with experimental data.

A numerical study on contact conditions, dynamic resistance, and nugget size of resistance spot weld joints of AISI 1008 steel sheets