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Up to the present not a few sutdies on calculation of temperature distribution in resistance spot weld have been reported. In these studies, however, electrical contact area between two sheets being welded was not taken into consideration. Hence, their results of numerical calculation did not coincide with their experimental data.In this study the authors derived the following formula for calculating the electric contact area under pressure by means of theory of elasticity, i.e., dc=de+ktwherein dc is diameter of contact area; de, electrode diameter; t, plate thickness; k, constant. It is to be noted that the above formula does not contain the term of electrode force. However, the constant k is dependent on electrode force, hence, the formula might be said to involve electrode force term implicitly. The validity of the formula was confirmed by the results of photoeleastic experiment.On the basis of the above finding and the experimental result that the contact area initially formed is kept practically unchanged during the entire process of welding, they derived the following formula for determining the optimum welding condititon for mild steel sheets of equal thickness, namely, s=7.63×107 (de+0.8t)4/I2wherein s is welding time (see); de, electrode diameter (cm); t, plate thickness (cm); I, welding current (A). The formula elucidates a useful relation between temperature rise in the contact zone and welding current.This formula is proved to be correct by the welding experiments with the newly designed weld specimens.

Study on Determination of the Optimum Welding Condition in Resistance Spot Weldng