Numerical modelling of the mechanical behavior of hybrid joint obtained by spot welding and bonding

Abstract Hybrid joints can be obtained using two or more techniques to attach two materials. This technique was well discussed, in the last two decades, for the use of different welding process. The development of new structural adhesives improved the use of adhesive bonding in the manufacturing sector to join assemblies, specialty aerospace and automotive industries. Compared to the common welding methods, adhesive bonding has many advantages such as simplified process, favorable fatigue properties, and the ability to join dissimilar metals. Weld bonding as a hybrid welding method combines welding and adhesive bonding to join metals. This work presents a numerical model based on the finite element method to assess the mechanical response of spot weld and hybrid joints composed by the combination of spot welding and bonding. The numerical model considers constitutive and geometric nonlinearities and is used to study the stress distribution and failure of the spot welding and weld bonding joints. A cohesive zone model is used to represent the adhesive bonding behavior. Numerical results are developed to assess the joints capability of the supporting loading and the stiffness joints. Experimental data obtained from previous works is used to calibrate the numerical model.