[{"quality_controlled":"1","file_date_updated":"2026-07-18T12:04:02Z","citation":{"mla":"Yang, Keke, et al. “A Physics-Guided Hybrid Framework for Online Pre-Expulsion Prediction in Resistance Spot Welding.” <i>Journal of Manufacturing Processes</i>, vol. 174, Elsevier BV, 2026, pp. 135–53, doi:<a href=\"https://doi.org/10.1016/j.jmapro.2026.07.042\">10.1016/j.jmapro.2026.07.042</a>.","bibtex":"@article{Yang_Li_Beck_Hein_Meschut_2026, title={A physics-guided hybrid framework for online pre-expulsion prediction in resistance spot welding}, volume={174}, DOI={<a href=\"https://doi.org/10.1016/j.jmapro.2026.07.042\">10.1016/j.jmapro.2026.07.042</a>}, journal={Journal of Manufacturing Processes}, publisher={Elsevier BV}, author={Yang, Keke and Li, Chong and Beck, Robert and Hein, David and Meschut, Gerson}, year={2026}, pages={135–153} }","ama":"Yang K, Li C, Beck R, Hein D, Meschut G. A physics-guided hybrid framework for online pre-expulsion prediction in resistance spot welding. <i>Journal of Manufacturing Processes</i>. 2026;174:135-153. doi:<a href=\"https://doi.org/10.1016/j.jmapro.2026.07.042\">10.1016/j.jmapro.2026.07.042</a>","ieee":"K. Yang, C. Li, R. Beck, D. Hein, and G. Meschut, “A physics-guided hybrid framework for online pre-expulsion prediction in resistance spot welding,” <i>Journal of Manufacturing Processes</i>, vol. 174, pp. 135–153, 2026, doi: <a href=\"https://doi.org/10.1016/j.jmapro.2026.07.042\">10.1016/j.jmapro.2026.07.042</a>.","apa":"Yang, K., Li, C., Beck, R., Hein, D., &#38; Meschut, G. (2026). A physics-guided hybrid framework for online pre-expulsion prediction in resistance spot welding. <i>Journal of Manufacturing Processes</i>, <i>174</i>, 135–153. <a href=\"https://doi.org/10.1016/j.jmapro.2026.07.042\">https://doi.org/10.1016/j.jmapro.2026.07.042</a>","short":"K. Yang, C. Li, R. Beck, D. Hein, G. Meschut, Journal of Manufacturing Processes 174 (2026) 135–153.","chicago":"Yang, Keke, Chong Li, Robert Beck, David Hein, and Gerson Meschut. “A Physics-Guided Hybrid Framework for Online Pre-Expulsion Prediction in Resistance Spot Welding.” <i>Journal of Manufacturing Processes</i> 174 (2026): 135–53. <a href=\"https://doi.org/10.1016/j.jmapro.2026.07.042\">https://doi.org/10.1016/j.jmapro.2026.07.042</a>."},"oa":"1","has_accepted_license":"1","status":"public","user_id":"65085","ddc":["600"],"volume":174,"page":"135-153","_id":"66541","publisher":"Elsevier BV","abstract":[{"text":"Expulsion in resistance spot welding (RSW) causes weld quality fluctuations and increases quality-control effort in high-volume manufacturing. Existing data-driven studies have mainly addressed post-occurrence expulsion detection, process-end classification, or the identification of influencing factors, whereas online monitoring requires short-term risk estimation before the event occurs. In this study, expulsion prediction is formulated as a sliding-window-based pre-expulsion risk estimation task for the currently welded spot. A physics-guided hybrid GRU-XGBoost ensemble is developed to combine temporal learning from dynamic resistance and electrode-force signals with process-physics-related scalar features describing heat input, resistance state, and force response. The framework was evaluated on 2730 valid welds, including 588 expulsion and 2142 non-expulsion welds, using weld-grouped five-fold cross-validation with fold-level working-point selection. The ensemble achieved an area under the ROC curve of 0.945 ± 0.004 and a weld-level recall of 90.6 ± 3.7% at an average false alarm rate of 9.8 ± 0.2%, outperforming both individual branches. For the 533 correctly warned expulsion welds, the median early-warning lead time was 56 ms. These results indicate that online, physically interpretable pre-expulsion risk prediction is feasible under low-false-alarm constraints within the investigated RSW configuration and provide a basis for future adaptive monitoring and control studies.","lang":"eng"}],"publication":"Journal of Manufacturing Processes","type":"journal_article","keyword":["Resistance spot welding","Expulsion prediction","Physics-guided machine learning","Hybrid ensemble modelling","Process monitoring"],"department":[{"_id":"157"}],"file":[{"creator":"kekeyang","date_created":"2026-07-18T12:04:02Z","file_name":"1-s2.0-S1526612526007012-main.pdf","access_level":"closed","file_size":10864983,"relation":"main_file","date_updated":"2026-07-18T12:04:02Z","file_id":"66542","success":1,"content_type":"application/pdf"}],"date_created":"2026-07-18T12:03:15Z","publication_status":"published","date_updated":"2026-07-18T12:07:50Z","article_type":"original","intvolume":"       174","title":"A physics-guided hybrid framework for online pre-expulsion prediction in resistance spot welding","year":"2026","publication_identifier":{"issn":["1526-6125"]},"author":[{"full_name":"Yang, Keke","first_name":"Keke","orcid":"0000-0001-9201-9304","last_name":"Yang","id":"65085"},{"full_name":"Li, Chong","last_name":"Li","first_name":"Chong"},{"id":"38279","full_name":"Beck, Robert","orcid":"0000-0001-9056-4528","last_name":"Beck","first_name":"Robert"},{"last_name":"Hein","first_name":"David","full_name":"Hein, David","id":"7728"},{"first_name":"Gerson","last_name":"Meschut","orcid":"0000-0002-2763-1246","full_name":"Meschut, Gerson","id":"32056"}],"doi":"10.1016/j.jmapro.2026.07.042","main_file_link":[{"open_access":"1"}],"language":[{"iso":"eng"}]},{"ddc":["670"],"user_id":"65085","volume":124,"page":"489-502","publisher":"Elsevier BV","_id":"54847","has_accepted_license":"1","status":"public","oa":"1","quality_controlled":"1","file_date_updated":"2024-06-23T21:59:20Z","citation":{"chicago":"Yang, Keke, Bassel El-Sari, Viktoria Olfert, Zhuoqun Wang, Max Biegler, Michael Rethmeier, and Gerson Meschut. “Expulsion Prevention in Resistance Spot Welding of Dissimilar Joints with Ultra-High Strength Steel: An Analysis of the Mechanism and Effect of Preheating Current.” <i>Journal of Manufacturing Processes</i> 124 (2024): 489–502. <a href=\"https://doi.org/10.1016/j.jmapro.2024.06.034\">https://doi.org/10.1016/j.jmapro.2024.06.034</a>.","short":"K. Yang, B. El-Sari, V. Olfert, Z. Wang, M. Biegler, M. Rethmeier, G. Meschut, Journal of Manufacturing Processes 124 (2024) 489–502.","apa":"Yang, K., El-Sari, B., Olfert, V., Wang, Z., Biegler, M., Rethmeier, M., &#38; Meschut, G. (2024). Expulsion prevention in resistance spot welding of dissimilar joints with ultra-high strength steel: An analysis of the mechanism and effect of preheating current. <i>Journal of Manufacturing Processes</i>, <i>124</i>, 489–502. <a href=\"https://doi.org/10.1016/j.jmapro.2024.06.034\">https://doi.org/10.1016/j.jmapro.2024.06.034</a>","ieee":"K. Yang <i>et al.</i>, “Expulsion prevention in resistance spot welding of dissimilar joints with ultra-high strength steel: An analysis of the mechanism and effect of preheating current,” <i>Journal of Manufacturing Processes</i>, vol. 124, pp. 489–502, 2024, doi: <a href=\"https://doi.org/10.1016/j.jmapro.2024.06.034\">10.1016/j.jmapro.2024.06.034</a>.","ama":"Yang K, El-Sari B, Olfert V, et al. Expulsion prevention in resistance spot welding of dissimilar joints with ultra-high strength steel: An analysis of the mechanism and effect of preheating current. <i>Journal of Manufacturing Processes</i>. 2024;124:489-502. doi:<a href=\"https://doi.org/10.1016/j.jmapro.2024.06.034\">10.1016/j.jmapro.2024.06.034</a>","bibtex":"@article{Yang_El-Sari_Olfert_Wang_Biegler_Rethmeier_Meschut_2024, title={Expulsion prevention in resistance spot welding of dissimilar joints with ultra-high strength steel: An analysis of the mechanism and effect of preheating current}, volume={124}, DOI={<a href=\"https://doi.org/10.1016/j.jmapro.2024.06.034\">10.1016/j.jmapro.2024.06.034</a>}, journal={Journal of Manufacturing Processes}, publisher={Elsevier BV}, author={Yang, Keke and El-Sari, Bassel and Olfert, Viktoria and Wang, Zhuoqun and Biegler, Max and Rethmeier, Michael and Meschut, Gerson}, year={2024}, pages={489–502} }","mla":"Yang, Keke, et al. “Expulsion Prevention in Resistance Spot Welding of Dissimilar Joints with Ultra-High Strength Steel: An Analysis of the Mechanism and Effect of Preheating Current.” <i>Journal of Manufacturing Processes</i>, vol. 124, Elsevier BV, 2024, pp. 489–502, doi:<a href=\"https://doi.org/10.1016/j.jmapro.2024.06.034\">10.1016/j.jmapro.2024.06.034</a>."},"doi":"10.1016/j.jmapro.2024.06.034","main_file_link":[{"open_access":"1","url":"https://www.sciencedirect.com/science/article/pii/S1526612524006145"}],"language":[{"iso":"eng"}],"date_updated":"2024-10-18T06:59:27Z","publication_status":"published","intvolume":"       124","article_type":"original","title":"Expulsion prevention in resistance spot welding of dissimilar joints with ultra-high strength steel: An analysis of the mechanism and effect of preheating current","year":"2024","author":[{"id":"65085","first_name":"Keke","last_name":"Yang","orcid":"0000-0001-9201-9304","full_name":"Yang, Keke"},{"full_name":"El-Sari, Bassel","last_name":"El-Sari","first_name":"Bassel"},{"id":"5974","full_name":"Olfert, Viktoria","first_name":"Viktoria","last_name":"Olfert"},{"first_name":"Zhuoqun","last_name":"Wang","full_name":"Wang, Zhuoqun"},{"first_name":"Max","last_name":"Biegler","full_name":"Biegler, Max"},{"first_name":"Michael","last_name":"Rethmeier","full_name":"Rethmeier, Michael"},{"last_name":"Meschut","orcid":"0000-0002-2763-1246","first_name":"Gerson","full_name":"Meschut, Gerson","id":"32056"}],"publication_identifier":{"issn":["1526-6125"]},"keyword":["Expulsion Resistance spot welding Finite element modelling Preheating Weldable current range Ultra-high strength steel"],"type":"journal_article","department":[{"_id":"157"}],"file":[{"creator":"kekeyang","date_created":"2024-06-23T21:59:20Z","date_updated":"2024-06-23T21:59:20Z","relation":"main_file","access_level":"closed","file_size":12432409,"file_name":"1-s2.0-S1526612524006145-main.pdf","content_type":"application/pdf","success":1,"file_id":"54848"}],"date_created":"2024-06-23T21:58:29Z","abstract":[{"text":"The widespread adoption of ultra-high strength steels, due to their high bulk resistivity, intensifies expulsion issues in resistance spot welding (RSW), deteriorating both the spot weld and surface quality. This study presents a novel approach to prevent expulsion by employing a preheating current. Through characteristic analysis of joint formation under critical welding current, the importance of plastic material encapsulation around the weld nugget (plastic shell) at high temperatures in preventing expulsion is highlighted. To evaluate the effect of preheating on the plastic shell and understand its mechanism in expulsion prevention, a two-dimensional welding simulation model for dissimilar ultra-high strength steel joints was established. The results showed that optimal preheating enhances the thickness of the plastic shell, improving its ability to encapsulate the weld nugget during the primary welding phase, thereby diminishing expulsion risks. Experimental validation confirmed that by employing the optimal preheating current, the maximum nugget diameter was enhanced to 9.42 mm, marking an increase of 13.4 % and extending the weldable current range by 27.5 %. Under quasi-static cross-tensile loading, joints with preheating demonstrated a 7.9 % enhancement in maximum load-bearing capacity compared to joints without preheating, showing a reproducible and complete pull-out failure mode within the heat-affected zone. This study offers a prevention method based on underlying mechanisms, providing a new perspective for future research on welding parameter optimization with the aim of expulsion prevention.","lang":"eng"}],"publication":"Journal of Manufacturing Processes"}]