An integrated computational model was developed by considering microstructural heterogeneity and residual stress of spot welds. The model consists of a resistance spot weld process model and a local mechanical model. The resistance spot weld process model is used to predict residual stress distribution, which is mapped into the local mechanical model. The hardness distribution of a spot weld is measured experimentally, and then converted into the tensile strength which is mapped into the local mechanical model. The local mechanical model is then used to predict the load response functions and failure modes of DP 590 spot welds. The predictions have been compared with DP 590 spot weld experiments.
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