TY - JOUR

T1 - Validated multi-physical finite element modelling of the spot welding process of the advanced high strength steel dp1200hd

AU - Prabitz, Konstantin

AU - Pichler, Marlies

AU - Antretter, Thomas

AU - Schubert, Holger

AU - Hilpert, Benjamin

AU - Gruber, Martin

AU - Sierlinger, Robert

AU - Ecker, Werner

N1 - Publisher Copyright: © 2021 by the authors. Licensee MDPI, Basel, Switzerland.

PY - 2021/9/18

Y1 - 2021/9/18

N2 - Resistance spot welding (RSW) is a common joining technique in the production of car bodies in white for example, because of its high degree of automation, its short process time, and its reliability. While different steel grades and even dissimilar metals can be joined with this method, the current paper focuses on similar joints of galvanized advanced high strength steel (AHSS), namely dual phase steel with a yield strength of 1200 MPa and high ductility (DP1200HD). This material offers potential for light-weight design. The current work presents a multi-physical finite element (FE) model of the RSW process which gives insights into the local loading and material state, and which forms the basis for future investigations of the local risk of liquid metal assisted cracking and the effect of different process parameters on this risk. The model covers the evolution of the electrical, thermal, mechanical, and metallurgical fields during the complete spot welding process. Phase transformations like base material to austenite and further to steel melt during heating and all relevant transformations while cooling are considered. The model was fully parametrized based on lab scale material testing, accompanying model-based parameter determination, and literature data, and was validated against a large variety of optically inspected burst opened spot welds and micrographs of the welds.

AB - Resistance spot welding (RSW) is a common joining technique in the production of car bodies in white for example, because of its high degree of automation, its short process time, and its reliability. While different steel grades and even dissimilar metals can be joined with this method, the current paper focuses on similar joints of galvanized advanced high strength steel (AHSS), namely dual phase steel with a yield strength of 1200 MPa and high ductility (DP1200HD). This material offers potential for light-weight design. The current work presents a multi-physical finite element (FE) model of the RSW process which gives insights into the local loading and material state, and which forms the basis for future investigations of the local risk of liquid metal assisted cracking and the effect of different process parameters on this risk. The model covers the evolution of the electrical, thermal, mechanical, and metallurgical fields during the complete spot welding process. Phase transformations like base material to austenite and further to steel melt during heating and all relevant transformations while cooling are considered. The model was fully parametrized based on lab scale material testing, accompanying model-based parameter determination, and literature data, and was validated against a large variety of optically inspected burst opened spot welds and micrographs of the welds.

KW - Advanced high strength steels

KW - Finite element simulation

KW - Phase transformation

KW - Resistance spot welding

KW - Zinc coated sheets

UR - http://www.scopus.com/inward/record.url?scp=85115354354&partnerID=8YFLogxK

U2 - 10.3390/ma14185411

DO - 10.3390/ma14185411

M3 - Article

AN - SCOPUS:85115354354

VL - 14.2021

JO - Materials

JF - Materials

SN - 1996-1944

IS - 18

M1 - 5411

ER -