Theoretical analysis of shunting effect in resistance spot welding (RSW) of AA2219

Shunting effect is the loss of electrical current via the secondary circuit provided due to existence of previous nugget in a series of welding spots. This phenomenon is important for products containing intermittent spots. In this study, a theoretical model is developed for shunting effect in resistance spot welding for aluminum alloy 2219. Welding distance together with welding current and time is included in the model to analyze the shunting effect on final nugget quality. Thermal and electrical interactions are considered in the model as well as geometrical aspects of the process. Temperature dependence of material properties, integration through the whole volume of the nugget and heat-affected zone, and assuming a simple cooling mechanism are the most important modifications designated in the proposed theoretical model. Predicted results of nugget diameter are compatible with experimental and finite element analysis results.