---
_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. Journal of
Manufacturing Processes. 2026;174:135-153. doi:10.1016/j.jmapro.2026.07.042
apa: Yang, K., Li, C., Beck, R., Hein, D., & Meschut, G. (2026). A physics-guided
hybrid framework for online pre-expulsion prediction in resistance spot welding.
Journal of Manufacturing Processes, 174, 135–153. https://doi.org/10.1016/j.jmapro.2026.07.042
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={10.1016/j.jmapro.2026.07.042},
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.” Journal of Manufacturing Processes 174 (2026): 135–53. https://doi.org/10.1016/j.jmapro.2026.07.042.'
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,” Journal
of Manufacturing Processes, vol. 174, pp. 135–153, 2026, doi: 10.1016/j.jmapro.2026.07.042.'
mla: Yang, Keke, et al. “A Physics-Guided Hybrid Framework for Online Pre-Expulsion
Prediction in Resistance Spot Welding.” Journal of Manufacturing Processes,
vol. 174, Elsevier BV, 2026, pp. 135–53, doi:10.1016/j.jmapro.2026.07.042.
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: '67569'
abstract:
- lang: eng
text: "\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 \r\n
\ 1\r\n \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 "
article_number: '14644207261497691'
author:
- first_name: Pia Katharina
full_name: Kaimann, Pia Katharina
id: '44935'
last_name: Kaimann
- first_name: J
full_name: Sarris, J
last_name: Sarris
- first_name: Robert
full_name: Beck, Robert
id: '38279'
last_name: Beck
orcid: 0000-0001-9056-4528
- first_name: Mathias
full_name: Bobbert, Mathias
id: '7850'
last_name: Bobbert
- first_name: M
full_name: Lechner, M
last_name: Lechner
- first_name: Gerson
full_name: Meschut, Gerson
id: '32056'
last_name: Meschut
orcid: 0000-0002-2763-1246
citation:
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. Proceedings of the Institution
of Mechanical Engineers, Part L: Journal of Materials: Design and Applications.
Published online 2026. doi:10.1177/14644207261497691'
apa: 'Kaimann, P. K., Sarris, J., Beck, R., Bobbert, M., Lechner, M., & 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.
Proceedings of the Institution of Mechanical Engineers, Part L: Journal of
Materials: Design and Applications, Article 14644207261497692. https://doi.org/10.1177/14644207261497691'
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={10.1177/14644207261497691},
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} }'
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.” Proceedings of the Institution of Mechanical Engineers, Part L:
Journal of Materials: Design and Applications, 2026. https://doi.org/10.1177/14644207261497691.'
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,” Proceedings
of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design
and Applications, Art. no. 14644207261497692, 2026, doi: 10.1177/14644207261497691.'
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.” Proceedings of the Institution of Mechanical Engineers,
Part L: Journal of Materials: Design and Applications, 14644207261497692,
SAGE Publications, 2026, doi:10.1177/14644207261497691.'
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).'
date_created: 2026-10-16T11:33:10Z
date_updated: 2026-10-16T11:47:04Z
department:
- _id: '43'
- _id: '157'
doi: 10.1177/14644207261497691
language:
- iso: eng
project:
- _id: '130'
name: 'TRR 285: Methodenentwicklung zur mechanischen Fügbarkeit in wandlungsfähigen
Prozessketten'
- _id: '133'
name: TRR 285 - Project Area C
- _id: '146'
name: TRR 285 - Subproject C02
publication: 'Proceedings of the Institution of Mechanical Engineers, Part L: Journal
of Materials: Design and Applications'
publication_identifier:
issn:
- 1464-4207
- 2041-3076
publication_status: published
publisher: SAGE Publications
quality_controlled: '1'
status: public
title: Comparative study of multi-range-capable rivet and standard self-piercing rivets
in aluminium-aluminium and ultra-high-strength steel-aluminium assemblies
type: journal_article
user_id: '44935'
year: '2026'
...
---
_id: '57742'
article_type: original
author:
- first_name: Max
full_name: Böhnke, Max
id: '45779'
last_name: Böhnke
- first_name: Christian Roman
full_name: Bielak, Christian Roman
id: '34782'
last_name: Bielak
- first_name: Robert
full_name: Beck, Robert
id: '38279'
last_name: Beck
orcid: 0000-0001-9056-4528
- first_name: Mathias
full_name: Bobbert, Mathias
id: '7850'
last_name: Bobbert
- first_name: Gerson
full_name: Meschut, Gerson
id: '32056'
last_name: Meschut
orcid: 0000-0002-2763-1246
citation:
ama: Böhnke M, Bielak CR, Beck R, Bobbert M, Meschut G. Development of a friction
model for the numerical simulation of clinching processes. Friction. Published
online 2024. doi:10.26599/frict.2025.9441052
apa: Böhnke, M., Bielak, C. R., Beck, R., Bobbert, M., & Meschut, G. (2024).
Development of a friction model for the numerical simulation of clinching processes.
Friction. https://doi.org/10.26599/frict.2025.9441052
bibtex: '@article{Böhnke_Bielak_Beck_Bobbert_Meschut_2024, title={Development of
a friction model for the numerical simulation of clinching processes}, DOI={10.26599/frict.2025.9441052},
journal={Friction}, publisher={Tsinghua University Press}, author={Böhnke, Max
and Bielak, Christian Roman and Beck, Robert and Bobbert, Mathias and Meschut,
Gerson}, year={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.” Friction, 2024. https://doi.org/10.26599/frict.2025.9441052.
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,” Friction,
2024, doi: 10.26599/frict.2025.9441052.'
mla: Böhnke, Max, et al. “Development of a Friction Model for the Numerical Simulation
of Clinching Processes.” Friction, Tsinghua University Press, 2024, doi:10.26599/frict.2025.9441052.
short: M. Böhnke, C.R. Bielak, R. Beck, M. Bobbert, G. Meschut, Friction (2024).
date_created: 2024-12-11T14:45:57Z
date_updated: 2026-05-12T14:08:38Z
department:
- _id: '157'
doi: 10.26599/frict.2025.9441052
language:
- iso: eng
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
publication_identifier:
issn:
- 2223-7690
- 2223-7704
publication_status: published
publisher: Tsinghua University Press
quality_controlled: '1'
status: public
title: Development of a friction model for the numerical simulation of clinching processes
type: journal_article
user_id: '7850'
year: '2024'
...
---
_id: '22225'
author:
- first_name: Martin
full_name: Ivanjko, Martin
id: '59675'
last_name: Ivanjko
- first_name: Robert
full_name: Beck, Robert
id: '38279'
last_name: Beck
- first_name: Gerson
full_name: Meschut, Gerson
id: '32056'
last_name: Meschut
orcid: 0000-0002-2763-1246
- first_name: Jonas
full_name: Zweck, Jonas
last_name: Zweck
- first_name: Thomas
full_name: Richter, Thomas
last_name: Richter
citation:
ama: 'Ivanjko M, Beck R, Meschut G, Zweck J, Richter T. Development of an adaptive,
sensor-based FDS-robot-system. In: ; 2021.'
apa: Ivanjko, M., Beck, R., Meschut, G., Zweck, J., & Richter, T. (2021). Development
of an adaptive, sensor-based FDS-robot-system. Presented at the Joining in Car
Body Engineering 2021, Bad Nauheim.
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}
}'
chicago: Ivanjko, Martin, Robert Beck, Gerson Meschut, Jonas Zweck, and Thomas Richter.
“Development of an Adaptive, Sensor-Based FDS-Robot-System,” 2021.
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.
mla: Ivanjko, Martin, et al. Development of an Adaptive, Sensor-Based FDS-Robot-System.
2021.
short: 'M. Ivanjko, R. Beck, G. Meschut, J. Zweck, T. Richter, in: 2021.'
conference:
end_date: 2021-04-22
location: Bad Nauheim
name: Joining in Car Body Engineering 2021
start_date: 2021-04-19
date_created: 2021-05-25T09:20:49Z
date_updated: 2022-01-06T06:55:29Z
department:
- _id: '157'
language:
- iso: eng
status: public
title: Development of an adaptive, sensor-based FDS-robot-system
type: conference
user_id: '59675'
year: '2021'
...
---
_id: '20678'
author:
- first_name: Christian Roman
full_name: Bielak, Christian Roman
id: '34782'
last_name: Bielak
- first_name: Max
full_name: Böhnke, Max
id: '45779'
last_name: Böhnke
- first_name: Robert
full_name: Beck, Robert
id: '38279'
last_name: Beck
- first_name: Mathias
full_name: Bobbert, Mathias
id: '7850'
last_name: Bobbert
- first_name: Gerson
full_name: Meschut, Gerson
id: '32056'
last_name: Meschut
orcid: 0000-0002-2763-1246
citation:
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 . Journal
of Advanced Joining Processes . Published online 2020. doi:https://doi.org/10.1016/j.jajp.2020.100038
apa: Bielak, C. R., Böhnke, M., Beck, R., Bobbert, M., & Meschut, G. (2020).
Numerical analysis of the robustness of clinching process considering the pre-forming
of the parts . Journal of Advanced Joining Processes. . https://doi.org/10.1016/j.jajp.2020.100038
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={https://doi.org/10.1016/j.jajp.2020.100038},
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} }'
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 .” Journal of Advanced Joining Processes. ,
2020. https://doi.org/10.1016/j.jajp.2020.100038.
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 ,” Journal of Advanced Joining Processes. , 2020, doi: https://doi.org/10.1016/j.jajp.2020.100038.'
mla: Bielak, Christian Roman, et al. “Numerical Analysis of the Robustness of Clinching
Process Considering the Pre-Forming of the Parts .” Journal of Advanced Joining
Processes. , Elsevier, 2020, doi:https://doi.org/10.1016/j.jajp.2020.100038.
short: C.R. Bielak, M. Böhnke, R. Beck, M. Bobbert, G. Meschut, Journal of Advanced
Joining Processes. (2020).
date_created: 2020-12-02T16:21:34Z
date_updated: 2022-03-24T09:39:11Z
department:
- _id: '157'
doi: https://doi.org/10.1016/j.jajp.2020.100038
keyword:
- Clinching
- process simulation
- FEM
- pre-straining
- sensitivity analysis
language:
- iso: eng
project:
- _id: '130'
grant_number: '418701707'
name: 'TRR 285: TRR 285'
- _id: '131'
name: 'TRR 285 - A: TRR 285 - Project Area A'
- _id: '135'
name: 'TRR 285 – A01: TRR 285 - Subproject A01'
publication: 'Journal of Advanced Joining Processes. '
publication_identifier:
unknown:
- https://doi.org/10.1016/j.jajp.2020.100038
publication_status: published
publisher: Elsevier
status: public
title: 'Numerical analysis of the robustness of clinching process considering the
pre-forming of the parts '
type: journal_article
user_id: '34782'
year: '2020'
...