Process Simulation of Resistance Weld Bonding and Automotive Light-weight Materials

This paper presents the latest developments in numerical simulation of resistance welding especially with the new functions for simulation of microstructures, weld bonding and spot welding of new light-weight materials. The fundamental functions in SORPAS® are built on coupled modeling of mechanical, electrical, thermal and metallurgical processes, which are essential for simulation of resistance welding process to predict the welding results and evaluate the weldability of materials.

These functions have been further extended with new functions for optimization of welding process parameters and predicting welding process window, for weld planning with optimal welding parameter settings, and for modeling microstructures and hardness distribution after welding. Latest developments have been made on simulation of resistance welding with nonconductive materials for applications in weld bonding with combination of adhesive bonding and spot welding, and in spot welding of the new lightweight sandwich steels.