MORE | Spring 2020

Analyzing the Effect of Contact Resistance on the Temperature Field Evolution During Resistance Spot Welding

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Resistance spot welding is used to join metal sheets together by sandwiching workpieces between two electrodes passing a high current through the assembly which generates resistive heating that melts the workpieces together. The primary research question answered is how the contact resistance influences the temperature field evolution of a copper-aluminum-copper stackup during resistance spot welding. This was investigated by developing a finite element model in ANSYS that included the copper-aluminum-copper geometry and the respective contact resistances that vary with temperature and pressure. The results can be used to improve the durability of spot-welded components within car batteries.

Student researcher

Molly Victoria Rhodes

Mechanical engineering

Hometown: Gilbert, Arizona, United States

Graduation date: Fall 2020