This paper provides a finite element model to predict the nugget development during resistance spot welding of steel sheets. The model employs the coupled thermal-electricalmechanical analysis capability of Abaqus. The contact area and the interface pressure distribution are determined from a thermal-mechanical coupling in the analysis. The knowledge of interface pressure allows for accurate prediction of interfacial heat and electrical resistance, which have a dominant role in Joule heat generation. Temperature-dependent material properties for the coupled analysis are used. The significant parameters in the spot-welding process are current magnitude and frequency, welding time, sheet material and thickness, geometry of electrodes, and electrode force.
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