This proposal is to develop a simulation of the spot welding process using finite element techniques to portray the coupled electrical, thermal, and mechanical cycles seen during this type of welding. This simulation will allow study of how variations in process parameters affect weld formation. Of particular interest are the size of the weld nugget formed and the magnitude of the residual stresses in the weld zone which can be related to fatigue life of the weld. This type of analysis to determine the residual stresses in the weld zone is novel. Experimental work to validate the approach is planned. Spot welding is an important manufacturing process, especially for the automotive industry. This research can lead to a better understanding of residual stress development in this type of welding and to valuable design guidelines.
