Abstract Carbon fiber reinforced plastic (CFRP) is a prospective lightweight material in automobile industry. However, joining metal and CFRP is a great challenge. In the present study, an innovative process called coaxial one-side resistance spot welding (COS-RSW) is proposed to fabricate Al5052 (Al) and CFRP joints. Based upon our newly developed finite element code JWRIAN, the electric-thermal-mechanical coupled process of COS-RSW is modeled and validated with experiments. The influences of welding current, welding time and electrode force on CFRP molten zone are investigated in detail. The results show that the depth of molten zone has a strong correlation with both welding current and welding time. A relative low welding current or short welding time that results in the Al/CFRP interface temperature below the melting temperature of the resin matrix is insufficient to form a sound connection between the two sheets. While excessive current or too long welding time may lead to overheating of CFRP and decomposition of the resin matrix, which increases the risk of weak joining. Furthermore, it is found that the depth of molten zone increases even at the cooling stage, which indicates accurate simulation for both the heating and the cooling stages of the COS-RSW process is indispensable.

中文翻译：

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Al5052与CFRP异种材料同轴单面电阻点焊数值分析

摘要 碳纤维增强塑料（CFRP）是汽车工业中一种有前景的轻量化材料。然而，连接金属和 CFRP 是一个巨大的挑战。在本研究中，提出了一种称为同轴单侧电阻点焊 (COS-RSW) 的创新工艺来制造 Al5052 (Al) 和 CFRP 接头。基于我们新开发的有限元程序JWRIAN，对COS-RSW的电-热-机耦合过程进行了建模和实验验证。详细研究了焊接电流、焊接时间和电极力对CFRP熔区的影响。结果表明，熔区深度与焊接电流和焊接时间都具有很强的相关性。导致 Al/CFRP 界面温度低于树脂基体熔化温度的相对较低的焊接电流或较短的焊接时间不足以在两块板材之间形成良好的连接。而过大的电流或过长的焊接时间可能会导致CFRP过热和树脂基体分解，从而增加连接不牢固的风险。此外，发现即使在冷却阶段熔融区的深度也会增加，这表明对 COS-RSW 过程的加热和冷却阶段的准确模拟是必不可少的。