Using a New Contact Resistance Model for Investigating Mechanical Properties of Hastelloy X Welded Joints in Small Scale Resistance Spot Welding

Nowadays, due to the need for miniaturization, small scale resistance spot welding is of interest. The key factor that determines the nugget size is contact resistance. In this paper a new equation is provided to calculate the electrical contact resistance. The model can predict the high temperature contours and the nugget configuration efficiently. Also, a set-up was constructed to verify the model and investigate the effects of parameters on the mechanical properties of Hastelloy X welded joints. DOE analysis is done to recognize the effect of parameters on the nugget diameter, maximum load, and nugget height. It was concluded that the size of the nugget enlarges by increasing welding current and time. The nugget diameter decreases with increase of force.