A Parametric Study of Resistance Spot Welding of a Dual-Phase Steel Using Finite Element Analysis


This research uses Finite Element Analysis (FEA) to simulate the influence of processing parameters on Resistance Spot Welding of a dual-phase steel. The simulations and boundary conditions were run using the FEA software SYSWELD. The model utilized accounts for several interactions between electro-kinetics, heat transfer, phase transformations, and mechanical behavior. The parameters varied in this study included, the electrical current intensity, the welding time, the sheet thickness, the electrode face radius, and the squeeze force. The design of experiments (DOE) method was used to analyze the main effects and interactions of the various parameters over a realistic range of values. The simulation results supplied weld properties, which were analyzed using the analysis of variance (ANOVA) technique to quantify the parameters' effects and their significance. The current intensity was found to be the most influential factor with an expanding effect on the size of molten zone and the heat affected zone. The sheet thickness and welding time also showed significant contributions. The effect of the other parameters was less significant. The importance of this study is to find the process window for welding parameters that can result in the desired weld properties.

Meeting Name

8th Pacific Rim International Congress on Advanced Materials and Processing (2013: Aug. 4-9, Waikoloa, HI)


Materials Science and Engineering


Materials Australia (MA)
The Chinese Society for Metals (CSM)
The Japan Institute of Metals (JIM)
The Korean Institute of Metals and Materials (KIM)
The Minerals, Metals and Materials Society (TMS)

Keywords and Phrases

Analysis of variance (ANOVA); Design of experiments; Resistance welding; Welding; Current intensity; Electrical current; Influential factors; Mechanical behavior; Processing parameters; Welding parameters; Finite element method; Finite element analysis; Resistance spot welding; SYSWELD

International Standard Book Number (ISBN)


Document Type

Article - Conference proceedings

Document Version


File Type





© 2013 John Wiley & Sons Inc., All rights reserved.

Publication Date

01 Aug 2013