The single-sided resistance spot welding process is analyzed by a 3D numerical study of sheet-to-tube joining. Finite element simulations are carried out in SORPAS® 3D. Two levels of electrode force and five levels of welding current are simulated. The overall effects of changing current and force are discussed and special focus is put on the sensitivity to the electrode force and the potential of melt penetration to the inside of the tube. The electrode force is critical because the level is a compromise between sufficient contact area on one side and indentation and local deformation of the tube on the other side. The potential of melt penetration through the thickness of the tube during the hold time is a result of heat conduction in the tube material and lack of an electrode on the inside of the tube, which results in poor cooling of the inner tube surface.
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