Evaluating Spot Welds of Dissimilar Metals Via Integrated Mechanical Testing and Finite Element Modeling
Year: 2025
Type: article
Abstract: This study investigates resistance spot welding of dissimilar materials, namely 37.2 carbon steel, 304 stainless steel, and commercial aluminium. The effect of welding parameters on nugget growth, tensile shear strength, and failure modes in various material combinations was investigated using a combined experimental and finite element modeling (FEM) approach. Experimental studies included a welding current range (5-15 kA) and time range (10-30 cycles), complemented by tensile testing and hardness measurements. It was observed that Carbon Steel-Stainless Steel (CS-SS) joints achieved the highest strength (9.5 kN at 9 kA), while aluminium-containing joints exhibited lower strengths but required higher optimal currents. Hardness profiles showed extensive variations across weld zones, particularly for aluminium-steel joints. Failure mode analysis showed a prevalence of pullout failures for CS-SS joints, in contrast to more interfacial failures in aluminium-steel combinations. A finite element model was developed and validated against experimental data, showing excellent predictive capability for nugget size and joint strength (R²>0.96). This study contributes to the development of dissimilar material welding by providing new insights into parameter optimization, failure mechanisms, and industrial application, particularly for automotive and aerospace industries.
Institutions: Mustansiriyah University, Islamic University of Najaf
Language: English
Subfield: Mechanical Engineering
Field: Engineering
Domain: Physical Sciences
Open Access status: gold
Estimated APC paid: $107
Funder: Mustansiriyah University
OpenAlex ID: W4411817188