Finite element simulation of high speed pulse welding of high specific strength metal alloys

High specific strength metal alloys as aluminium, nickel and titanium alloys are suitable to reduce weight in components for transportation industry. Beside component performances, manufacturability and production efficiency must be considered when substituting classical steels with high specific strength metal alloys. In a way similar to resistance welding a sound autogenously joint can be achieved by discharging a very high current pulse over a very short time that is called high pulsed welding or capacitative discharge welding. In this paper a numerical model was built with the aim to support the evaluation, via a computer aided approach, of the effects of this technique on the high pulsed weldability of some lightweight metal alloys. The model aimed to reproduce the electrical, thermal and mechanical aspects of the high pulse welding process and to evaluate the temperature profile, the piece displacement, the effects of different welding parameters on the weld seam.