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Numerical simulation of resistance spot welding of Al to zinc-coated steel with improved representation of contact interactions.pdf
International Journal of Heat and Mass Transfer 101 (2016) 749–763
Contents lists available at ScienceDirect
International Journal of Heat and Mass Transfer
journal homepage: /locate/ijhmt
Numerical simulation of resistance spot welding of Al to zinc-coated steel with improved representation of contact interactions
Zixuan Wan a, Hui-Ping Wang b,?, Min Wang a,?, Blair E. Carlson b, David R. Sigler b
a Shanghai Key Laboratory of Materials Laser Processing and Modi?cation, School of Material Science and Engineering, Shanghai Jiao Tong University, Shanghai 200240, PR China b Manufacturing System Research, GM Global RD, Warren, MI 48090, USA
article info
Article history: Received 4 January 2016 Received in revised form 3 May 2016 Accepted 6 May 2016 Available online 9 June 2016
Keywords: Resistance pot welding Numerical simulation Al to steel welding Electrical contact resistance Thermal contact resistance Intermetallic compound
abstract
The resistance spot welding (RSW) process involves electrical, thermal, mechanical and metallurgical ?elds and contact interactions across faying interfaces. The contact interactions include mechanical, electrical and thermal contacts where the electrical and thermal conduction across the faying interface are affected strongly by the mechanical contact pressure and temperature at the interface in addition to material composition and surface conditions. However, representation of the contact interactions is often simpli?ed with no or limited consideration of a combination of above-mentioned effects in state-of-theart numerical simulation models due to extremely limited availability of electrical and thermal contact resistance data at various pressures and temperatures. As a result, existing numerical models, mainly to simulate the process of dissimilar RSW process like Al to steel, often have dif?culties in accurately capturing the dynamic voltage response, especially during the initial stage when the contact interactions start to engage
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