Validated Multi-Physical Finite Element Modelling of the Spot Welding Process of the Advanced High Strength Steel DP1200HD
Resistance spot welding (RSW) is a common joining technique in the production of car bodies in white for example, because of its high degree of automation, its short process time, and its reliability. While different steel grades and even dissimilar metals can be joined with this method, the current...
| Main Authors: | , , , , , , , |
|---|---|
| Format: | Article |
| Language: | English |
| Published: |
MDPI AG
2021-09-01
|
| Series: | Materials |
| Subjects: | |
| Online Access: | https://www.mdpi.com/1996-1944/14/18/5411 |
| _version_ | 1797518379470290944 |
|---|---|
| author | Konstantin Prabitz Marlies Pichler Thomas Antretter Holger Schubert Benjamin Hilpert Martin Gruber Robert Sierlinger Werner Ecker |
| author_facet | Konstantin Prabitz Marlies Pichler Thomas Antretter Holger Schubert Benjamin Hilpert Martin Gruber Robert Sierlinger Werner Ecker |
| author_sort | Konstantin Prabitz |
| collection | DOAJ |
| description | Resistance spot welding (RSW) is a common joining technique in the production of car bodies in white for example, because of its high degree of automation, its short process time, and its reliability. While different steel grades and even dissimilar metals can be joined with this method, the current paper focuses on similar joints of galvanized advanced high strength steel (AHSS), namely dual phase steel with a yield strength of 1200 MPa and high ductility (DP1200HD). This material offers potential for light-weight design. The current work presents a multi-physical finite element (FE) model of the RSW process which gives insights into the local loading and material state, and which forms the basis for future investigations of the local risk of liquid metal assisted cracking and the effect of different process parameters on this risk. The model covers the evolution of the electrical, thermal, mechanical, and metallurgical fields during the complete spot welding process. Phase transformations like base material to austenite and further to steel melt during heating and all relevant transformations while cooling are considered. The model was fully parametrized based on lab scale material testing, accompanying model-based parameter determination, and literature data, and was validated against a large variety of optically inspected burst opened spot welds and micrographs of the welds. |
| first_indexed | 2024-03-10T07:29:03Z |
| format | Article |
| id | doaj.art-7bd34ef39cb448d49203e38f6b6cf885 |
| institution | Directory Open Access Journal |
| issn | 1996-1944 |
| language | English |
| last_indexed | 2024-03-10T07:29:03Z |
| publishDate | 2021-09-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Materials |
| spelling | doaj.art-7bd34ef39cb448d49203e38f6b6cf8852023-11-22T14:03:36ZengMDPI AGMaterials1996-19442021-09-011418541110.3390/ma14185411Validated Multi-Physical Finite Element Modelling of the Spot Welding Process of the Advanced High Strength Steel DP1200HDKonstantin Prabitz0Marlies Pichler1Thomas Antretter2Holger Schubert3Benjamin Hilpert4Martin Gruber5Robert Sierlinger6Werner Ecker7Materials Center Leoben Forschung GmbH, Roseggerstraße 12, 8700 Leoben, AustriaMaterials Center Leoben Forschung GmbH, Roseggerstraße 12, 8700 Leoben, AustriaInstitute of Mechanics, Montanuniversitaet Leoben, Franz Josef-Straße 18, 8700 Leoben, AustriaMercedes-Benz AG, 71059 Sindelfingen, GermanyMercedes-Benz AG, 71059 Sindelfingen, GermanyVoestalpine Stahl GmbH, voestalpine-Straße 3, 4020 Linz, AustriaVoestalpine Stahl GmbH, voestalpine-Straße 3, 4020 Linz, AustriaMaterials Center Leoben Forschung GmbH, Roseggerstraße 12, 8700 Leoben, AustriaResistance spot welding (RSW) is a common joining technique in the production of car bodies in white for example, because of its high degree of automation, its short process time, and its reliability. While different steel grades and even dissimilar metals can be joined with this method, the current paper focuses on similar joints of galvanized advanced high strength steel (AHSS), namely dual phase steel with a yield strength of 1200 MPa and high ductility (DP1200HD). This material offers potential for light-weight design. The current work presents a multi-physical finite element (FE) model of the RSW process which gives insights into the local loading and material state, and which forms the basis for future investigations of the local risk of liquid metal assisted cracking and the effect of different process parameters on this risk. The model covers the evolution of the electrical, thermal, mechanical, and metallurgical fields during the complete spot welding process. Phase transformations like base material to austenite and further to steel melt during heating and all relevant transformations while cooling are considered. The model was fully parametrized based on lab scale material testing, accompanying model-based parameter determination, and literature data, and was validated against a large variety of optically inspected burst opened spot welds and micrographs of the welds.https://www.mdpi.com/1996-1944/14/18/5411resistance spot weldingfinite element simulationadvanced high strength steelsphase transformationzinc coated sheets |
| spellingShingle | Konstantin Prabitz Marlies Pichler Thomas Antretter Holger Schubert Benjamin Hilpert Martin Gruber Robert Sierlinger Werner Ecker Validated Multi-Physical Finite Element Modelling of the Spot Welding Process of the Advanced High Strength Steel DP1200HD Materials resistance spot welding finite element simulation advanced high strength steels phase transformation zinc coated sheets |
| title | Validated Multi-Physical Finite Element Modelling of the Spot Welding Process of the Advanced High Strength Steel DP1200HD |
| title_full | Validated Multi-Physical Finite Element Modelling of the Spot Welding Process of the Advanced High Strength Steel DP1200HD |
| title_fullStr | Validated Multi-Physical Finite Element Modelling of the Spot Welding Process of the Advanced High Strength Steel DP1200HD |
| title_full_unstemmed | Validated Multi-Physical Finite Element Modelling of the Spot Welding Process of the Advanced High Strength Steel DP1200HD |
| title_short | Validated Multi-Physical Finite Element Modelling of the Spot Welding Process of the Advanced High Strength Steel DP1200HD |
| title_sort | validated multi physical finite element modelling of the spot welding process of the advanced high strength steel dp1200hd |
| topic | resistance spot welding finite element simulation advanced high strength steels phase transformation zinc coated sheets |
| url | https://www.mdpi.com/1996-1944/14/18/5411 |
| work_keys_str_mv | AT konstantinprabitz validatedmultiphysicalfiniteelementmodellingofthespotweldingprocessoftheadvancedhighstrengthsteeldp1200hd AT marliespichler validatedmultiphysicalfiniteelementmodellingofthespotweldingprocessoftheadvancedhighstrengthsteeldp1200hd AT thomasantretter validatedmultiphysicalfiniteelementmodellingofthespotweldingprocessoftheadvancedhighstrengthsteeldp1200hd AT holgerschubert validatedmultiphysicalfiniteelementmodellingofthespotweldingprocessoftheadvancedhighstrengthsteeldp1200hd AT benjaminhilpert validatedmultiphysicalfiniteelementmodellingofthespotweldingprocessoftheadvancedhighstrengthsteeldp1200hd AT martingruber validatedmultiphysicalfiniteelementmodellingofthespotweldingprocessoftheadvancedhighstrengthsteeldp1200hd AT robertsierlinger validatedmultiphysicalfiniteelementmodellingofthespotweldingprocessoftheadvancedhighstrengthsteeldp1200hd AT wernerecker validatedmultiphysicalfiniteelementmodellingofthespotweldingprocessoftheadvancedhighstrengthsteeldp1200hd |