Modelling of the temperature distribution of spot-weldable composite/metal joints

Resistance spot welding is the most economical joining method for the production of automotive steel bodies. In modern car body construction, however, its future applicability is limited due to the growing mix of materials in multi-material design. In response to increasing weight reduction requirements to protect the environment and natural resources, lightweight materials, and fibre-reinforced plastics (FRP) in particular, are more and more used in modern vehicle bodies. To facilitate the future joining of FRP/steel structures with resistance spot welding, spot-weldable force-introduction elements may be embedded in the laminate as a joining interface. When welding the so-called inserts, thermal damage to the surrounding polymer should be avoided, as this is the only way to calculate the strength of the joint correctly. For this purpose, the paper presents a numerical model that allows the prediction of the temperature propagation during spot welding of FRP/steel joints with embedded inserts. The simulative approach is subsequently validated by comparison with experimentally determined temperature curves and in doing so, an excellent model prediction can be noted.