Effect of weld parameters on weld quality in sheet to tube joining with simulation and experimental research

Single sided resistance spot welding (SSRSW) developed from RSW is a feasible plan to join vehicle structure to closed-form tube and is increasingly used in automobile manufacturing. Successful implementation of SSRSW to improve structural crashworthiness and reduce vehicle weight requires knowledge of issues related not only to joint performance but also processing requirements. In this study, effects of weld processing parameters on weld quality were researched by numerical and experimental method. It was found that the width of the weld lobe is narrow and the weldability of sheet and tube is bad under constant electrode force. Reasonable processing parameter matching is very important to the sheet to tube welding.