Cross-wire welding analyzed by experiments and simulations

Resistance welding of crossed wires, e.g. used in the electronics industry or fabrication wire meshes, is analyzed by both experiments and numerical modeling using an electro-thermo-mechanical finite element formulation. Welding machine characteristics are discussed necessary requirements to type concluded. Cross-wire stainless steel, structural steel aluminum presented, differences process flash formation discussed. It shown that joints primarily due solid-state bonding local melting. The simulations compare well at low weld settings, while remaining challenges for simulation high settings identified terms mesh detailed description follow up electrode force movement.