Cross-wire welding analyzed by experiments and simulations

Resistance welding of crossed wires, e.g. used in the electronics industry or in fabrication of wire meshes, is analyzed by both experiments and numerical modeling using an electro-thermo-mechanical finite element formulation. Welding machine characteristics are discussed and the necessary requirements to the type of welding machine are concluded. Cross-wire welding of stainless steel, structural steel and aluminum are presented, and differences in the welding process and flash formation are discussed. It is shown that the joints are primarily due to solid-state bonding and local melting. The simulations compare well to the experiments at low weld settings, while remaining challenges for simulation of high weld settings are identified in terms of requirements to the mesh and detailed description of the machine follow up of the electrode force and movement.