AI-assisted process design in resistance spot welding

Complex Material Combinations AI-Assisted Process Design in Resistance Spot Welding

2026-06-12 A guest post by Leonie Methler * | Translated by AI 2 min Reading Time

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Taiwan Machine Tool & Accessory Builders' Association (TMBA)

SIMTOS (Seoul International Machine Tool Show)

Resistance spot welding (RSW) is one of the most important joining processes, particularly in automotive manufacturing. The increasing complexity of requirements for modern vehicles, driven by lightweighting strategies, electromobility, and stricter safety standards, poses challenges for this proven method.

Welding gun used for joining a B-pillar under laboratory conditions at Fraunhofer-IPK.(Source: Fraunhofer-IPK) — Welding gun used for joining a B-pillar under laboratory conditions at Fraunhofer-IPK.
(Source: Fraunhofer-IPK)

The joining of different materials with varying thicknesses, which often exhibit differing electrical and thermal behavior, results in issues with weldability, reproducibility, and connection quality. The use of thin-walled, high- and ultra-high-strength steels in multi-sheet connections in particular requires process-specific expertise, as unequal material and transition resistances often make the bonding of the thin outer layer a challenge. Determining parameters for these combinations is time- and material-intensive if based solely on experimental data, as specified in SEP 1220-2.

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Date: 08.12.2025

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