[{"ddc":["620"],"language":[{"iso":"eng"}],"publication":"Journal of Manufacturing Processes","abstract":[{"text":"This study addresses the challenge of insufficient weld penetration in the outer thin low-carbon steel during\r\nresistance spot welding of three-layer dissimilar stack-ups containing advanced high-strength steels. To overcome\r\nthermal imbalance constraints, an innovative strategy leveraging plastic shell containment is proposed to elevate\r\nthe expulsion-free heat input threshold. By applying a combined preheating and ramping current profile, a coordinated “shell-first, nugget-second” sequence is achieved. This mechanism creates a solid-state barrier prior to\r\nrapid fusion, effectively preventing expulsion. Experimental results demonstrate that while the reference\r\nconstant-current schedule fails to maintain a process window under a 2 mm initial gap (IG) disturbance, the\r\nproposed strategy significantly enhances process stability. It increases the maximum expulsion-free heat input by\r\n24 % (to 6338 J) under normal conditions and by 77 % (to 6482 J) under the IG condition. Crucially, the\r\nincreased heat input drives nugget growth across all interfaces, achieving a penetration depth of 0.38 mm (48 %\r\npenetration ratio) in the low-carbon steel sheet under the gap condition. These findings validate the strategy’s\r\neffectiveness in ensuring weld quality and robustness, which is further confirmed by its transferability to a lowerresistivity DX54D cover sheet.","lang":"eng"}],"file":[{"access_level":"closed","file_id":"63392","file_name":"1-s2.0-S1526612525013568-main.pdf","file_size":21431773,"creator":"kekeyang","date_created":"2025-12-22T08:21:51Z","date_updated":"2025-12-22T08:21:51Z","relation":"main_file","success":1,"content_type":"application/pdf"}],"publisher":"Elsevier BV","date_created":"2025-12-22T08:20:34Z","title":"Process window expansion with transferable applicability in three-layer dissimilar steel resistance spot welding via expulsion prevention","quality_controlled":"1","issue":"Special issue entitled: ‘Trends on spot joining’ published in Journal of Manufacturing Processes.","year":"2026","_id":"63391","user_id":"65085","department":[{"_id":"157"}],"article_type":"original","file_date_updated":"2025-12-22T08:21:51Z","type":"journal_article","status":"public","date_updated":"2025-12-22T08:24:19Z","oa":"1","author":[{"first_name":"Keke","last_name":"Yang","orcid":"0000-0001-9201-9304","full_name":"Yang, Keke","id":"65085"},{"first_name":"Leonhard","last_name":"Männer","id":"51255","full_name":"Männer, Leonhard"},{"full_name":"Wang, Zhuoqun","last_name":"Wang","first_name":"Zhuoqun"},{"first_name":"Viktoria","last_name":"Olfert","full_name":"Olfert, Viktoria","id":"5974"},{"first_name":"Yannic","last_name":"Böhm","id":"84119","full_name":"Böhm, Yannic"},{"last_name":"Hein","id":"7728","full_name":"Hein, David","first_name":"David"},{"first_name":"Gerson","full_name":"Meschut, Gerson","id":"32056","orcid":"0000-0002-2763-1246","last_name":"Meschut"}],"volume":157,"main_file_link":[{"url":"https://doi.org/10.1016/j.jmapro.2025.12.036","open_access":"1"}],"doi":"10.1016/j.jmapro.2025.12.036","publication_status":"published","publication_identifier":{"issn":["1526-6125"]},"has_accepted_license":"1","citation":{"ama":"Yang K, Männer L, Wang Z, et al. Process window expansion with transferable applicability in three-layer dissimilar steel resistance spot welding via expulsion prevention. <i>Journal of Manufacturing Processes</i>. 2026;157(Special issue entitled: ‘Trends on spot joining’ published in Journal of Manufacturing Processes.):984-1000. doi:<a href=\"https://doi.org/10.1016/j.jmapro.2025.12.036\">10.1016/j.jmapro.2025.12.036</a>","ieee":"K. Yang <i>et al.</i>, “Process window expansion with transferable applicability in three-layer dissimilar steel resistance spot welding via expulsion prevention,” <i>Journal of Manufacturing Processes</i>, vol. 157, no. Special issue entitled: ‘Trends on spot joining’ published in Journal of Manufacturing Processes., pp. 984–1000, 2026, doi: <a href=\"https://doi.org/10.1016/j.jmapro.2025.12.036\">10.1016/j.jmapro.2025.12.036</a>.","chicago":"Yang, Keke, Leonhard Männer, Zhuoqun Wang, Viktoria Olfert, Yannic Böhm, David Hein, and Gerson Meschut. “Process Window Expansion with Transferable Applicability in Three-Layer Dissimilar Steel Resistance Spot Welding via Expulsion Prevention.” <i>Journal of Manufacturing Processes</i> 157, no. Special issue entitled: ‘Trends on spot joining’ published in Journal of Manufacturing Processes. (2026): 984–1000. <a href=\"https://doi.org/10.1016/j.jmapro.2025.12.036\">https://doi.org/10.1016/j.jmapro.2025.12.036</a>.","bibtex":"@article{Yang_Männer_Wang_Olfert_Böhm_Hein_Meschut_2026, title={Process window expansion with transferable applicability in three-layer dissimilar steel resistance spot welding via expulsion prevention}, volume={157}, DOI={<a href=\"https://doi.org/10.1016/j.jmapro.2025.12.036\">10.1016/j.jmapro.2025.12.036</a>}, number={Special issue entitled: ‘Trends on spot joining’ published in Journal of Manufacturing Processes.}, journal={Journal of Manufacturing Processes}, publisher={Elsevier BV}, author={Yang, Keke and Männer, Leonhard and Wang, Zhuoqun and Olfert, Viktoria and Böhm, Yannic and Hein, David and Meschut, Gerson}, year={2026}, pages={984–1000} }","short":"K. Yang, L. Männer, Z. Wang, V. Olfert, Y. Böhm, D. Hein, G. Meschut, Journal of Manufacturing Processes 157 (2026) 984–1000.","mla":"Yang, Keke, et al. “Process Window Expansion with Transferable Applicability in Three-Layer Dissimilar Steel Resistance Spot Welding via Expulsion Prevention.” <i>Journal of Manufacturing Processes</i>, vol. 157, no. Special issue entitled: ‘Trends on spot joining’ published in Journal of Manufacturing Processes., Elsevier BV, 2026, pp. 984–1000, doi:<a href=\"https://doi.org/10.1016/j.jmapro.2025.12.036\">10.1016/j.jmapro.2025.12.036</a>.","apa":"Yang, K., Männer, L., Wang, Z., Olfert, V., Böhm, Y., Hein, D., &#38; Meschut, G. (2026). Process window expansion with transferable applicability in three-layer dissimilar steel resistance spot welding via expulsion prevention. <i>Journal of Manufacturing Processes</i>, <i>157</i>(Special issue entitled: ‘Trends on spot joining’ published in Journal of Manufacturing Processes.), 984–1000. <a href=\"https://doi.org/10.1016/j.jmapro.2025.12.036\">https://doi.org/10.1016/j.jmapro.2025.12.036</a>"},"page":"984-1000","intvolume":"       157"}]