Simulation of welding residual stresses in resistance spot welding, FE modeling and X-ray verification

In the present study, an electro-thermo-mechanical model is utilized to predict electrical potential, temperature and residual stress distributions during different stages of resistance spot welding. In order to improve accuracy, material properties including physical, thermal and mechanical properties supposed to be temperature-dependent. The employed model is capable of considering the effects of welding parameters such as heat input and welding time on residual stress distribution. The model results are then compared with the measured residual stresses and good agreement is observed. Predictions show that maximum tensile residual stresses are located at the weld center while they are reduced towards the nugget edge.