Recent progress in numerical simulation of resistance seam welding

The heat-affected zone of resistance seam weld moves with the rolling disc electrode, so the nugget laps with each other, then the nucleation process occurred in a closed state and cannot be observed. It is more difficult to accurately calculate the welding parameters and performance of joint in resistance seam welding than in spot welding. As a powerful analysis method, numerical simulation has solved problems in resistance seam welding field that the traditional analysis method cannot solve, and attracts more and more attention. This paper reviews the recent research achievements at home and abroad, compares the features of resistance seam welding and resistance spot welding, summaries the numerical simulation methods for welding current field, temperature field and stress field (strain field) in resistance seam welding process. It also concludes the intellectual control techniques for weld shape, weld tracking and nondestructive test. The principles of these methods and techniques are analyzed and discussed. The development of multi-parameters and multi-variable integrated model will be the research focus of numerical simulation of resistance seam welding process in the future. Developing advanced online real-time monitoring system and nondestructive test technology and corresponding numerical simulation technique will be important research fields in resistance seam welding.