Integrated Welding to Performance Simulations for Dissimilar Metals Joints

National Laboratory: 
Pacific Northwest National Laboratory
Computational Tools Class: 
Materials Processing
Processing/Manufacturing Class: 

Pacific Northwest National Laboratory offers an integrated manufacturing process simulation capability that can be used to predict the effects of different joining parameters on joint strength and performance in a component-level static or crash test. The capability includes fusion welding, resistance welding, impact-based welding, friction stir welding, and mechanical fastening (self-piercing riveting (SPR) and bolting).

Capability Bounds: 

The model can be used for similar and dissimilar metals joining and can cover solid-state and fusion welding and mechanical fastening.

Unique Aspects: 

This capability covers fusion welding, resistance spot welding, and solid-state joining (friction stir and impact pulse welding), as well as mechanical fastening for dissimilar metals. Modeling capabilities on fusion welding of similar metals may exist elsewhere. However, this capability involving dissimilar metal pairs is unique to PNNL.


Computational tools are developed, validated, and published by PNNL. The model uses commercial finite element software along with in-house-developed codes and user subroutines.

Single Point of Contact: 

Name: Erin Barker
Phone: 509-372-4727

  1. W Xu, X Sun. Numerical investigation of electromagnetic pulse welded interfaces between dissimilar metals. Science and Technology of Welding and Joining, 2015. DOI:
  2. X Sun and P Dong. Analysis of Aluminum Resistance Spot Welding Processes Using Coupled Finite Element Procedures, Welding Journal, Vol. 79, No. 8 (2000), pp. 215-s to 221-s.
  3. X Sun, EV Stephens and MA Khaleel. Effects of Fusion Zone Size and Failure Mode on Peak Load and Energy Absorption of Advanced High Strength Steel Spot Welds under Lapshear Loading Conditions, Engineering Failure Analysis, 15 (2008) 356–367.
Supporting Document(s):