Numerical simulation of resistance welding

Resistance welding is a fusion process that uses the heat generated by the Joule effect of a high-current electric current passing through the parts to be joined. The various processes (spot, seam, projection and flash) are described in the Resistance Welding article in this treatise.

This article focuses on process simulation rather than weld behavior simulation. Although the complementarity between these two approaches is obvious, examples of complete simulation (from welding to weld failure) are still very rare. We will show how the results of a process simulation can be used to simulate weld behavior.

We'll start by explaining the usefulness, principles of use and limitations of a numerical simulation tool in the study of resistance welding processes.

In the following, we will distinguish the three phases of model development: formulating hypotheses, obtaining and analyzing results, and validation.

In each case, the particularities of each process are described, along with examples from the literature. It should be noted that no examples of numerical modeling of flash butt welding have been identified. This is because the physical mechanisms involved (spark generation, material consumption) are different from those of other resistance welding processes. Consequently, it is not easy to extend the examples given below to flash butt welding. Numerical modeling of this process would first require a good understanding of the mechanisms involved.