An integrated approach for numerically predicting the failure of resistance spot welds

Abstract

In this study, a numerical approach was proposed to predict the failure of resistance spot welds, into which theoretical and empirical models as well as finite element (FE) model are integrated. In this approach, the hardness of spot welds was first evaluated and the estimated hardness was then used to determine the local mechanical properties. The weld geometry and boundary conditions were faithfully followed when generating the FE model. A Gurson-type damage model and a cohesive zone model were simultaneously considered for the two main failure modes, i.e. pull-out failure and interface failure. The predictions were validated by experimental observations. The successful estimation of critical nugget size, as an exemplary application, demonstrated the utility and reliability of this approach.