[{"publication":"Journal of Manufacturing Processes","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"}],"file":[{"creator":"kekeyang","date_created":"2026-07-18T12:04:02Z","access_level":"closed","file_size":10864983,"file_name":"1-s2.0-S1526612526007012-main.pdf","date_updated":"2026-07-18T12:04:02Z","relation":"main_file","content_type":"application/pdf","success":1,"file_id":"66542"}],"date_created":"2026-07-18T12:03:15Z","keyword":["Resistance spot welding","Expulsion prediction","Physics-guided machine learning","Hybrid ensemble modelling","Process monitoring"],"type":"journal_article","department":[{"_id":"157"}],"year":"2026","title":"A physics-guided hybrid framework for online pre-expulsion prediction in resistance spot welding","publication_identifier":{"issn":["1526-6125"]},"author":[{"orcid":"0000-0001-9201-9304","last_name":"Yang","first_name":"Keke","full_name":"Yang, Keke","id":"65085"},{"first_name":"Chong","last_name":"Li","full_name":"Li, Chong"},{"id":"38279","last_name":"Beck","first_name":"Robert","orcid":"0000-0001-9056-4528","full_name":"Beck, Robert"},{"id":"7728","full_name":"Hein, David","first_name":"David","last_name":"Hein"},{"id":"32056","full_name":"Meschut, Gerson","last_name":"Meschut","first_name":"Gerson","orcid":"0000-0002-2763-1246"}],"publication_status":"published","date_updated":"2026-07-18T12:07:50Z","article_type":"original","intvolume":"       174","main_file_link":[{"open_access":"1"}],"language":[{"iso":"eng"}],"doi":"10.1016/j.jmapro.2026.07.042","file_date_updated":"2026-07-18T12:04:02Z","citation":{"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>","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.","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>.","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>"},"quality_controlled":"1","oa":"1","status":"public","has_accepted_license":"1","page":"135-153","publisher":"Elsevier BV","_id":"66541","user_id":"65085","ddc":["600"],"volume":174},{"department":[{"_id":"43"},{"_id":"157"}],"type":"journal_article","date_created":"2026-10-16T11:33:10Z","abstract":[{"text":"<jats:p>\r\n                    The increasing use of aluminium alloys and ultra-high-strength steels, such as CP1000, in automotive lightweight design imposes stringent requirements on mechanical joining technologies. Self-piercing riveting (SPR) is widely used in multi-material structures; however, conventional rivet systems are limited ranges of material and sheet thickness. To address this limitation, Kappe et al. introduced versatile self-piercing riveting (V-SPR), which combines an extended punch actuator with a multi-range-capable rivet to enable joining of materials with tensile strengths up to 600 MPa without tool changes.\r\n                    <jats:sup>\r\n                      <jats:xref ref-type=\"bibr\">1</jats:xref>\r\n                    </jats:sup>\r\n                    This study presents a comparative investigation of a multi-range-capable rivet for V-SPR and conventional standard rivets in CP1000–aluminium and aluminium–aluminium joints. The analysis focuses on joint formation and mechanical performance under shear-tensile and cross-tensile loading. Metallographic cross-sections are used to characterise interlock formation, minimum die-side material thickness, and failure modes. Mechanical performance is evaluated using quasi-static tests, with emphasis on maximum load and failure mode. The experiments establish a demonstrated joinability matrix for the investigated sheet-thickness combinations using adapted punch and die motions. The results demonstrate the applicability of V-SPR to ultra-high-strength steel–aluminium and aluminium–aluminium joints. For the most industrially relevant combination investigated, St1.5–Al2.0 (CP1000–EN AW-6014), V-SPR achieves mechanical performance comparable to or higher than that of standard SPR while substantially reducing tool complexity through a single multi-range-capable rivet, a reduced die configuration, and fewer stack-specific changeovers. However, the independently driven inner and outer punches and active die increase actuator and control-system complexity.\r\n                  </jats:p>","lang":"eng"}],"publication":"Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications","doi":"10.1177/14644207261497691","language":[{"iso":"eng"}],"article_number":"14644207261497691","publication_status":"published","date_updated":"2026-10-16T11:47:04Z","publication_identifier":{"issn":["1464-4207","2041-3076"]},"author":[{"id":"44935","full_name":"Kaimann, Pia Katharina","last_name":"Kaimann","first_name":"Pia Katharina"},{"first_name":"J","last_name":"Sarris","full_name":"Sarris, J"},{"first_name":"Robert","last_name":"Beck","orcid":"0000-0001-9056-4528","full_name":"Beck, Robert","id":"38279"},{"first_name":"Mathias","last_name":"Bobbert","full_name":"Bobbert, Mathias","id":"7850"},{"full_name":"Lechner, M","first_name":"M","last_name":"Lechner"},{"last_name":"Meschut","orcid":"0000-0002-2763-1246","first_name":"Gerson","full_name":"Meschut, Gerson","id":"32056"}],"title":"Comparative study of multi-range-capable rivet and standard self-piercing rivets in aluminium-aluminium and ultra-high-strength steel-aluminium assemblies","year":"2026","project":[{"_id":"130","name":"TRR 285:  Methodenentwicklung zur mechanischen Fügbarkeit in wandlungsfähigen Prozessketten"},{"name":"TRR 285 - Project Area C","_id":"133"},{"name":"TRR 285 - Subproject C02","_id":"146"}],"quality_controlled":"1","citation":{"bibtex":"@article{Kaimann_Sarris_Beck_Bobbert_Lechner_Meschut_2026, title={Comparative study of multi-range-capable rivet and standard self-piercing rivets in aluminium-aluminium and ultra-high-strength steel-aluminium assemblies}, DOI={<a href=\"https://doi.org/10.1177/14644207261497691\">10.1177/14644207261497691</a>}, number={14644207261497692}, journal={Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications}, publisher={SAGE Publications}, author={Kaimann, Pia Katharina and Sarris, J and Beck, Robert and Bobbert, Mathias and Lechner, M and Meschut, Gerson}, year={2026} }","ama":"Kaimann PK, Sarris J, Beck R, Bobbert M, Lechner M, Meschut G. Comparative study of multi-range-capable rivet and standard self-piercing rivets in aluminium-aluminium and ultra-high-strength steel-aluminium assemblies. <i>Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications</i>. Published online 2026. doi:<a href=\"https://doi.org/10.1177/14644207261497691\">10.1177/14644207261497691</a>","mla":"Kaimann, Pia Katharina, et al. “Comparative Study of Multi-Range-Capable Rivet and Standard Self-Piercing Rivets in Aluminium-Aluminium and Ultra-High-Strength Steel-Aluminium Assemblies.” <i>Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications</i>, 14644207261497692, SAGE Publications, 2026, doi:<a href=\"https://doi.org/10.1177/14644207261497691\">10.1177/14644207261497691</a>.","short":"P.K. Kaimann, J. Sarris, R. Beck, M. Bobbert, M. Lechner, G. Meschut, Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications (2026).","chicago":"Kaimann, Pia Katharina, J Sarris, Robert Beck, Mathias Bobbert, M Lechner, and Gerson Meschut. “Comparative Study of Multi-Range-Capable Rivet and Standard Self-Piercing Rivets in Aluminium-Aluminium and Ultra-High-Strength Steel-Aluminium Assemblies.” <i>Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications</i>, 2026. <a href=\"https://doi.org/10.1177/14644207261497691\">https://doi.org/10.1177/14644207261497691</a>.","ieee":"P. K. Kaimann, J. Sarris, R. Beck, M. Bobbert, M. Lechner, and G. Meschut, “Comparative study of multi-range-capable rivet and standard self-piercing rivets in aluminium-aluminium and ultra-high-strength steel-aluminium assemblies,” <i>Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications</i>, Art. no. 14644207261497692, 2026, doi: <a href=\"https://doi.org/10.1177/14644207261497691\">10.1177/14644207261497691</a>.","apa":"Kaimann, P. K., Sarris, J., Beck, R., Bobbert, M., Lechner, M., &#38; Meschut, G. (2026). Comparative study of multi-range-capable rivet and standard self-piercing rivets in aluminium-aluminium and ultra-high-strength steel-aluminium assemblies. <i>Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications</i>, Article 14644207261497692. <a href=\"https://doi.org/10.1177/14644207261497691\">https://doi.org/10.1177/14644207261497691</a>"},"user_id":"44935","publisher":"SAGE Publications","_id":"67569","status":"public"},{"date_updated":"2026-05-12T14:08:38Z","publication_status":"published","article_type":"original","year":"2024","status":"public","title":"Development of a friction model for the numerical simulation of clinching processes","author":[{"id":"45779","first_name":"Max","last_name":"Böhnke","full_name":"Böhnke, Max"},{"id":"34782","full_name":"Bielak, Christian Roman","last_name":"Bielak","first_name":"Christian Roman"},{"full_name":"Beck, Robert","last_name":"Beck","orcid":"0000-0001-9056-4528","first_name":"Robert","id":"38279"},{"first_name":"Mathias","last_name":"Bobbert","full_name":"Bobbert, Mathias","id":"7850"},{"id":"32056","full_name":"Meschut, Gerson","first_name":"Gerson","orcid":"0000-0002-2763-1246","last_name":"Meschut"}],"publication_identifier":{"issn":["2223-7690","2223-7704"]},"doi":"10.26599/frict.2025.9441052","user_id":"7850","publisher":"Tsinghua University Press","_id":"57742","language":[{"iso":"eng"}],"quality_controlled":"1","project":[{"_id":"131","name":"TRR 285 - A: TRR 285 - Project Area A"},{"_id":"135","name":"TRR 285 – A01: TRR 285 - Subproject A01"},{"_id":"130","name":"TRR 285:  Methodenentwicklung zur mechanischen Fügbarkeit in wandlungsfähigen Prozessketten"}],"publication":"Friction","citation":{"short":"M. Böhnke, C.R. Bielak, R. Beck, M. Bobbert, G. Meschut, Friction (2024).","chicago":"Böhnke, Max, Christian Roman Bielak, Robert Beck, Mathias Bobbert, and Gerson Meschut. “Development of a Friction Model for the Numerical Simulation of Clinching Processes.” <i>Friction</i>, 2024. <a href=\"https://doi.org/10.26599/frict.2025.9441052\">https://doi.org/10.26599/frict.2025.9441052</a>.","apa":"Böhnke, M., Bielak, C. R., Beck, R., Bobbert, M., &#38; Meschut, G. (2024). Development of a friction model for the numerical simulation of clinching processes. <i>Friction</i>. <a href=\"https://doi.org/10.26599/frict.2025.9441052\">https://doi.org/10.26599/frict.2025.9441052</a>","ieee":"M. Böhnke, C. R. Bielak, R. Beck, M. Bobbert, and G. Meschut, “Development of a friction model for the numerical simulation of clinching processes,” <i>Friction</i>, 2024, doi: <a href=\"https://doi.org/10.26599/frict.2025.9441052\">10.26599/frict.2025.9441052</a>.","ama":"Böhnke M, Bielak CR, Beck R, Bobbert M, Meschut G. Development of a friction model for the numerical simulation of clinching processes. <i>Friction</i>. Published online 2024. doi:<a href=\"https://doi.org/10.26599/frict.2025.9441052\">10.26599/frict.2025.9441052</a>","bibtex":"@article{Böhnke_Bielak_Beck_Bobbert_Meschut_2024, title={Development of a friction model for the numerical simulation of clinching processes}, DOI={<a href=\"https://doi.org/10.26599/frict.2025.9441052\">10.26599/frict.2025.9441052</a>}, journal={Friction}, publisher={Tsinghua University Press}, author={Böhnke, Max and Bielak, Christian Roman and Beck, Robert and Bobbert, Mathias and Meschut, Gerson}, year={2024} }","mla":"Böhnke, Max, et al. “Development of a Friction Model for the Numerical Simulation of Clinching Processes.” <i>Friction</i>, Tsinghua University Press, 2024, doi:<a href=\"https://doi.org/10.26599/frict.2025.9441052\">10.26599/frict.2025.9441052</a>."},"type":"journal_article","department":[{"_id":"157"}],"date_created":"2024-12-11T14:45:57Z"},{"conference":{"start_date":"2021-04-19","name":"Joining in Car Body Engineering 2021","location":"Bad Nauheim","end_date":"2021-04-22"},"author":[{"full_name":"Ivanjko, Martin","first_name":"Martin","last_name":"Ivanjko","id":"59675"},{"id":"38279","last_name":"Beck","first_name":"Robert","full_name":"Beck, Robert"},{"full_name":"Meschut, Gerson","first_name":"Gerson","orcid":"0000-0002-2763-1246","last_name":"Meschut","id":"32056"},{"last_name":"Zweck","first_name":"Jonas","full_name":"Zweck, Jonas"},{"full_name":"Richter, Thomas","first_name":"Thomas","last_name":"Richter"}],"title":"Development of an adaptive, sensor-based FDS-robot-system","year":"2021","status":"public","date_updated":"2022-01-06T06:55:29Z","_id":"22225","language":[{"iso":"eng"}],"user_id":"59675","citation":{"mla":"Ivanjko, Martin, et al. <i>Development of an Adaptive, Sensor-Based FDS-Robot-System</i>. 2021.","ama":"Ivanjko M, Beck R, Meschut G, Zweck J, Richter T. Development of an adaptive, sensor-based FDS-robot-system. In: ; 2021.","bibtex":"@inproceedings{Ivanjko_Beck_Meschut_Zweck_Richter_2021, title={Development of an adaptive, sensor-based FDS-robot-system}, author={Ivanjko, Martin and Beck, Robert and Meschut, Gerson and Zweck, Jonas and Richter, Thomas}, year={2021} }","apa":"Ivanjko, M., Beck, R., Meschut, G., Zweck, J., &#38; Richter, T. (2021). Development of an adaptive, sensor-based FDS-robot-system. Presented at the Joining in Car Body Engineering 2021, Bad Nauheim.","ieee":"M. Ivanjko, R. Beck, G. Meschut, J. Zweck, and T. Richter, “Development of an adaptive, sensor-based FDS-robot-system,” presented at the Joining in Car Body Engineering 2021, Bad Nauheim, 2021.","short":"M. Ivanjko, R. Beck, G. Meschut, J. Zweck, T. Richter, in: 2021.","chicago":"Ivanjko, Martin, Robert Beck, Gerson Meschut, Jonas Zweck, and Thomas Richter. “Development of an Adaptive, Sensor-Based FDS-Robot-System,” 2021."},"date_created":"2021-05-25T09:20:49Z","department":[{"_id":"157"}],"type":"conference"},{"department":[{"_id":"157"}],"keyword":["Clinching","process simulation","FEM","pre-straining","sensitivity analysis"],"type":"journal_article","date_created":"2020-12-02T16:21:34Z","project":[{"_id":"130","grant_number":"418701707","name":"TRR 285: TRR 285"},{"name":"TRR 285 - A: TRR 285 - Project Area A","_id":"131"},{"_id":"135","name":"TRR 285 – A01: TRR 285 - Subproject A01"}],"citation":{"apa":"Bielak, C. R., Böhnke, M., Beck, R., Bobbert, M., &#38; Meschut, G. (2020). Numerical analysis of the robustness of clinching process considering the pre-forming of the parts . <i>Journal of Advanced Joining Processes. </i>. <a href=\"https://doi.org/10.1016/j.jajp.2020.100038\">https://doi.org/10.1016/j.jajp.2020.100038</a>","ieee":"C. R. Bielak, M. Böhnke, R. Beck, M. Bobbert, and G. Meschut, “Numerical analysis of the robustness of clinching process considering the pre-forming of the parts ,” <i>Journal of Advanced Joining Processes. </i>, 2020, doi: <a href=\"https://doi.org/10.1016/j.jajp.2020.100038\">https://doi.org/10.1016/j.jajp.2020.100038</a>.","chicago":"Bielak, Christian Roman, Max Böhnke, Robert Beck, Mathias Bobbert, and Gerson Meschut. “Numerical Analysis of the Robustness of Clinching Process Considering the Pre-Forming of the Parts .” <i>Journal of Advanced Joining Processes. </i>, 2020. <a href=\"https://doi.org/10.1016/j.jajp.2020.100038\">https://doi.org/10.1016/j.jajp.2020.100038</a>.","short":"C.R. Bielak, M. Böhnke, R. Beck, M. Bobbert, G. Meschut, Journal of Advanced Joining Processes.  (2020).","mla":"Bielak, Christian Roman, et al. “Numerical Analysis of the Robustness of Clinching Process Considering the Pre-Forming of the Parts .” <i>Journal of Advanced Joining Processes. </i>, Elsevier, 2020, doi:<a href=\"https://doi.org/10.1016/j.jajp.2020.100038\">https://doi.org/10.1016/j.jajp.2020.100038</a>.","ama":"Bielak CR, Böhnke M, Beck R, Bobbert M, Meschut G. Numerical analysis of the robustness of clinching process considering the pre-forming of the parts . <i>Journal of Advanced Joining Processes </i>. Published online 2020. doi:<a href=\"https://doi.org/10.1016/j.jajp.2020.100038\">https://doi.org/10.1016/j.jajp.2020.100038</a>","bibtex":"@article{Bielak_Böhnke_Beck_Bobbert_Meschut_2020, title={Numerical analysis of the robustness of clinching process considering the pre-forming of the parts }, DOI={<a href=\"https://doi.org/10.1016/j.jajp.2020.100038\">https://doi.org/10.1016/j.jajp.2020.100038</a>}, journal={Journal of Advanced Joining Processes. }, publisher={Elsevier}, author={Bielak, Christian Roman and Böhnke, Max and Beck, Robert and Bobbert, Mathias and Meschut, Gerson}, year={2020} }"},"publication":"Journal of Advanced Joining Processes. ","doi":"https://doi.org/10.1016/j.jajp.2020.100038","user_id":"34782","_id":"20678","publisher":"Elsevier","language":[{"iso":"eng"}],"date_updated":"2022-03-24T09:39:11Z","publication_status":"published","author":[{"id":"34782","full_name":"Bielak, Christian Roman","last_name":"Bielak","first_name":"Christian Roman"},{"id":"45779","first_name":"Max","last_name":"Böhnke","full_name":"Böhnke, Max"},{"id":"38279","last_name":"Beck","first_name":"Robert","full_name":"Beck, Robert"},{"id":"7850","full_name":"Bobbert, Mathias","last_name":"Bobbert","first_name":"Mathias"},{"id":"32056","orcid":"0000-0002-2763-1246","last_name":"Meschut","first_name":"Gerson","full_name":"Meschut, Gerson"}],"publication_identifier":{"unknown":["https://doi.org/10.1016/j.jajp.2020.100038"]},"status":"public","title":"Numerical analysis of the robustness of clinching process considering the pre-forming of the parts ","year":"2020"}]