Transactions of the Indian Institute of Metals

, Volume 72, Issue 2, pp 429–438 | Cite as

Finite Element-Based Parametric Studies of Nugget Diameter and Temperature Distribution in the Resistance Spot Welding of AISI 304 and AISI 316L Sheets

  • M. VigneshkumarEmail author
  • P. Ashoka Varthanan
  • Y. Maria Ambrose Raj
Technical Paper


Resistance spot welding (RSW) of dissimilar metals is prominent in automobile industries to utilize the material properties of both the metals. RSW of dissimilar austenitic stainless steel sheets (AISI 304/316L) is investigated in this paper by varying the process parameters such as welding current and weld time at three different levels. Tensile shear test and macrostructural examinations are carried out to analyze the performance of spot welds. A three-dimensional model is also developed using commercial finite element analysis software ABAQUS FEA to predict the nugget diameter and thermal distribution profile through simultaneous structural electrothermal analysis with temperature-dependent material properties. The generated model is validated by comparing the predicted nugget diameter with experimental nugget diameter. Experimental results show good coherence with the simulation results, and the macrostructure of the spot-welded joints indicates successful welding of dissimilar sheets with defect-free fusion zone.


Resistance spot welding (RSW) Finite element analysis Nugget diameter Interface temperature Tensile shear failure load (TSFL) 


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Copyright information

© The Indian Institute of Metals - IIM 2018

Authors and Affiliations

  1. 1.Department of Mechanical EngineeringSri Krishna College of Engineering and TechnologyCoimbatoreIndia
  2. 2.Renault Nissan Technology India Private LimitedChennaiIndia

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