A 3-D thermal model for resistance spot welding in aluminum is presented. The numerical model, validated with experimental findings, considers phase change and the associated weld-pool convection. A parametric study is performed to determine the influence of welding features such as faying surface (work - piece contact surface) contact resistance, current, electrode-work-piece surface-thermal-contact conductance and electrode-work-piece surface-thermal-contact conducance and electrode tip diameters have significant effects on the nugget and heat-affected-zone geometry.
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