---
_id: '66541'
abstract:
- lang: eng
  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.
article_type: original
author:
- first_name: Keke
  full_name: Yang, Keke
  id: '65085'
  last_name: Yang
  orcid: 0000-0001-9201-9304
- first_name: Chong
  full_name: Li, Chong
  last_name: Li
- first_name: Robert
  full_name: Beck, Robert
  id: '38279'
  last_name: Beck
  orcid: 0000-0001-9056-4528
- first_name: David
  full_name: Hein, David
  id: '7728'
  last_name: Hein
- first_name: Gerson
  full_name: Meschut, Gerson
  id: '32056'
  last_name: Meschut
  orcid: 0000-0002-2763-1246
citation:
  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>
  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>
  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} }'
  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>.'
  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>.'
  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>.
  short: K. Yang, C. Li, R. Beck, D. Hein, G. Meschut, Journal of Manufacturing Processes
    174 (2026) 135–153.
date_created: 2026-07-18T12:03:15Z
date_updated: 2026-07-18T12:07:50Z
ddc:
- '600'
department:
- _id: '157'
doi: 10.1016/j.jmapro.2026.07.042
file:
- access_level: closed
  content_type: application/pdf
  creator: kekeyang
  date_created: 2026-07-18T12:04:02Z
  date_updated: 2026-07-18T12:04:02Z
  file_id: '66542'
  file_name: 1-s2.0-S1526612526007012-main.pdf
  file_size: 10864983
  relation: main_file
  success: 1
file_date_updated: 2026-07-18T12:04:02Z
has_accepted_license: '1'
intvolume: '       174'
keyword:
- Resistance spot welding
- Expulsion prediction
- Physics-guided machine learning
- Hybrid ensemble modelling
- Process monitoring
language:
- iso: eng
main_file_link:
- open_access: '1'
oa: '1'
page: 135-153
publication: Journal of Manufacturing Processes
publication_identifier:
  issn:
  - 1526-6125
publication_status: published
publisher: Elsevier BV
quality_controlled: '1'
status: public
title: A physics-guided hybrid framework for online pre-expulsion prediction in resistance
  spot welding
type: journal_article
user_id: '65085'
volume: 174
year: '2026'
...
---
_id: '54847'
abstract:
- lang: eng
  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.
article_type: original
author:
- first_name: Keke
  full_name: Yang, Keke
  id: '65085'
  last_name: Yang
  orcid: 0000-0001-9201-9304
- first_name: Bassel
  full_name: El-Sari, Bassel
  last_name: El-Sari
- first_name: Viktoria
  full_name: Olfert, Viktoria
  id: '5974'
  last_name: Olfert
- first_name: Zhuoqun
  full_name: Wang, Zhuoqun
  last_name: Wang
- first_name: Max
  full_name: Biegler, Max
  last_name: Biegler
- first_name: Michael
  full_name: Rethmeier, Michael
  last_name: Rethmeier
- first_name: Gerson
  full_name: Meschut, Gerson
  id: '32056'
  last_name: Meschut
  orcid: 0000-0002-2763-1246
citation:
  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>'
  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>'
  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} }'
  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>.'
  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>.'
  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>.'
  short: K. Yang, B. El-Sari, V. Olfert, Z. Wang, M. Biegler, M. Rethmeier, G. Meschut,
    Journal of Manufacturing Processes 124 (2024) 489–502.
date_created: 2024-06-23T21:58:29Z
date_updated: 2024-10-18T06:59:27Z
ddc:
- '670'
department:
- _id: '157'
doi: 10.1016/j.jmapro.2024.06.034
file:
- access_level: closed
  content_type: application/pdf
  creator: kekeyang
  date_created: 2024-06-23T21:59:20Z
  date_updated: 2024-06-23T21:59:20Z
  file_id: '54848'
  file_name: 1-s2.0-S1526612524006145-main.pdf
  file_size: 12432409
  relation: main_file
  success: 1
file_date_updated: 2024-06-23T21:59:20Z
has_accepted_license: '1'
intvolume: '       124'
keyword:
- Expulsion Resistance spot welding Finite element modelling Preheating Weldable current
  range Ultra-high strength steel
language:
- iso: eng
main_file_link:
- open_access: '1'
  url: https://www.sciencedirect.com/science/article/pii/S1526612524006145
oa: '1'
page: 489-502
publication: Journal of Manufacturing Processes
publication_identifier:
  issn:
  - 1526-6125
publication_status: published
publisher: Elsevier BV
quality_controlled: '1'
status: public
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'
type: journal_article
user_id: '65085'
volume: 124
year: '2024'
...