Al5052-CFRP同轴单边电阻点焊的数值分析OACSTPCD

Coaxial one-side resistance spot welding(COS-RSW)is an advanced method of joining metal and carbon fibre re-inforced plastic(CFRP).In the present research,the author-developed finite element code JWRIAN-RSW was employed to model the electrical-thermal-mechanical coupled phenomena of COS-RSW between Al5052 and CFRP.The welding thermal cycle was predicted numerically and verified by experimental measurement.Cross-tension test was used to evaluate the me-chanical performance of joints,the influence of welding parameters on joining strength,fracture behaviours and interface morphology was clarified.The generation of molten zone dimension was also discussed.The results showed that the pre-dicted thermal cycle presented a good agreement with measurement,which indicated the effectiveness of numerical model.The COS-RSW joints presented two fracture modes.Low welding current resulted in a weak joining,interfacial failing and brittle fracture.The large current led to a strong bonding and ductile fracture,the failure occurred within the resin matrix.Be-sides,the molten zone of COS-RSW can grow up even in the early stages of cooling.Therefore,it was necessary to consider the cooling stage in the numerical model of COS-RSW to predict the molten zone dimension via peak temperature distribu-tion.