Particle simulation of nugget formation process during steel/aluminum alloy dissimilar resistance spot welding and thickness estimation of intermetallic compounds

A steel/aluminum alloy dissimilar resistance spot welding process was simulated by a three-dimensional smoothed particle hydrodynamics method. Furthermore, the time dependent increase of intermetallic compound thickness on joining interface estimated using numerical data temperature history obtained simulation. As result, steel sheet started to melt from center in direction and formed nugget, while aluminum nugget. The convection molten caused electromagnetic force promoted heat transfer at solid-liquid because gradient become steeper due conduction, whereas near nugget decreased. Moreover, estimation indicated that layer thicker thinner toward its edge. maximum be approximately 1 ?m, which same order magnitude as experimentally value. These results support validity computational model developed this study for simulating formation during estimating thickness.