Spotweld with no failure

Spot Welding is a type of resisting welding technique comes under the fusion welding category where heat and pressure both are applied in order to join two parts, the heat produced due to resistance of current flow through the material air gap, the heat generated is equal to I^2R and nugget formation happen
and then when held for few fractions of seconds the fusion between the part happens.
Spot weld strength plays a crucial importance to the overall vehicle structural integrity and crash safety. With the innovation of Advanced high strength steel (AHSS), prediction of spot-weld fracture is of paramount importance in current and future vehicle design.
Resistive spot welding (RSW) is the most common joining method in the automotive industry, particularly for BIW application. The main advantage of using RSW including high speed, low cost and the ability to volume automation. A typical vehicle contains approximately 2000-5000 spot welds. The joining strength is important to the overall structural integrity and vehicle crash safety.
Today automotive industry is mindful of reducing CO2 emissions an increasing fuel efficiency. To achieve these objectives, automakers are continuously working to reduce the overall vehicle weight.
Extensive use of Advanced high strength steel (AHSS) BIW is one of the ways to achieve this goal with the most recent innovation in AHSS, automotive industry has been able to use combination of low gage an high strength steel to design light weight body structure, However joining High-strength steel becomes challenging with lower gages, considering spot weld strength directly proportional to thickness of underlying sheet metal. Hence, spot-weld failure prediction during virtual design stage of vehicle development is of vital importance.
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