Estimation of the weldability of single-sided resistance spot welding

• A numerical analysis is used to estimate the weldability of single-sided resistance spot welding.
• Welding experiments are performed to verify the reliability of the welding method.
• The Lobe curve with respect to welding time and current is obtained.
• A certain level of tensile strength can be obtained at the range of welding variables for the optimal nugget size.

A single-sided spot welding technique is investigated by numerical analysis using a commercial CAE package to estimate the weldability. The reliability of the method is verified by the welding experiment performed under conditions similar to those of a real product. Several conditions are analyzed to find an optimal condition set, including the boundary condition for the ground location and the electrical contact resistance. The resulting Lobe curve with respect to welding time and current is obtained. The weldability of the single-sided spot welding specimen is estimated through the tensile strength test. A certain level of tensile strength can be obtained at the range of welding variables for the optimal nugget sizes, which supports the reliability of the single-sided RSW.