Numerical Simulation of Resistance Spot Welding of 304 Thin-walled Stainless Steel

Abstract Resistance spot welding is a widely used welding process for thin plates in industries such as aerospace and automotive. This process involves the combination of heat, force, and electricity, and the development of numerical simulation technology for welding processes has enabled the simulation of complex welding phenomena. Numerical simulation can reduce the need for extensive experimental work and improves welding production efficiency. In this article, the focus is on studying the temperature field and process parameters of resistance spot welding of (0.2+0.2 mm) 304 stainless steel. Initially, a three-dimensional symmetric model was created using Solid Works, and then Abaqus is used to perform a numerical analysis of the thermal-electric three-field coupling. The impact of welding parameters (welding current and welding time) on the temperature field and nugget diameter are analyzed. Next, welding experiments are conducted on the workpiece using different welding times and welding currents. The morphology and diameter changes of the molten material nucleus are observed using a high-magnification digital microscope. The results of the numerical simulation analysis and spot welding experiment analysis for resistance spot welding of 304 stainless steel with an equal thickness of 0.2+0.2 mm show a high level of consistency. Finally, tensile testing is carried out on the solder joints, combining this with the diameter to evaluate their strength and quality for the determination of the optimal welding process parameters.