---
_id: '63391'
abstract:
- lang: eng
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."
article_type: original
author:
- first_name: Keke
full_name: Yang, Keke
id: '65085'
last_name: Yang
orcid: 0000-0001-9201-9304
- first_name: Leonhard
full_name: Männer, Leonhard
id: '51255'
last_name: Männer
- first_name: Zhuoqun
full_name: Wang, Zhuoqun
last_name: Wang
- first_name: Viktoria
full_name: Olfert, Viktoria
id: '5974'
last_name: Olfert
- first_name: Yannic
full_name: Böhm, Yannic
id: '84119'
last_name: Böhm
- 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, Männer L, Wang Z, et al. Process window expansion with transferable
applicability in three-layer dissimilar steel resistance spot welding via expulsion
prevention. Journal of Manufacturing Processes. 2026;157(Special issue
entitled: ‘Trends on spot joining’ published in Journal of Manufacturing Processes.):984-1000.
doi:10.1016/j.jmapro.2025.12.036'
apa: 'Yang, K., Männer, L., Wang, Z., Olfert, V., Böhm, Y., Hein, D., & Meschut,
G. (2026). Process window expansion with transferable applicability in three-layer
dissimilar steel resistance spot welding via expulsion prevention. Journal
of Manufacturing Processes, 157(Special issue entitled: ‘Trends on
spot joining’ published in Journal of Manufacturing Processes.), 984–1000. https://doi.org/10.1016/j.jmapro.2025.12.036'
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={10.1016/j.jmapro.2025.12.036},
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}
}'
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.”
Journal of Manufacturing Processes 157, no. Special issue entitled: ‘Trends
on spot joining’ published in Journal of Manufacturing Processes. (2026): 984–1000.
https://doi.org/10.1016/j.jmapro.2025.12.036.'
ieee: 'K. Yang et al., “Process window expansion with transferable applicability
in three-layer dissimilar steel resistance spot welding via expulsion prevention,”
Journal of Manufacturing Processes, vol. 157, no. Special issue entitled:
‘Trends on spot joining’ published in Journal of Manufacturing Processes., pp.
984–1000, 2026, doi: 10.1016/j.jmapro.2025.12.036.'
mla: 'Yang, Keke, et al. “Process Window Expansion with Transferable Applicability
in Three-Layer Dissimilar Steel Resistance Spot Welding via Expulsion Prevention.”
Journal of Manufacturing Processes, vol. 157, no. Special issue entitled:
‘Trends on spot joining’ published in Journal of Manufacturing Processes., Elsevier
BV, 2026, pp. 984–1000, doi:10.1016/j.jmapro.2025.12.036.'
short: K. Yang, L. Männer, Z. Wang, V. Olfert, Y. Böhm, D. Hein, G. Meschut, Journal
of Manufacturing Processes 157 (2026) 984–1000.
date_created: 2025-12-22T08:20:34Z
date_updated: 2025-12-22T08:24:19Z
ddc:
- '620'
department:
- _id: '157'
doi: 10.1016/j.jmapro.2025.12.036
file:
- access_level: closed
content_type: application/pdf
creator: kekeyang
date_created: 2025-12-22T08:21:51Z
date_updated: 2025-12-22T08:21:51Z
file_id: '63392'
file_name: 1-s2.0-S1526612525013568-main.pdf
file_size: 21431773
relation: main_file
success: 1
file_date_updated: 2025-12-22T08:21:51Z
has_accepted_license: '1'
intvolume: ' 157'
issue: 'Special issue entitled: ‘Trends on spot joining’ published in Journal of Manufacturing
Processes.'
language:
- iso: eng
main_file_link:
- open_access: '1'
url: https://doi.org/10.1016/j.jmapro.2025.12.036
oa: '1'
page: 984-1000
publication: Journal of Manufacturing Processes
publication_identifier:
issn:
- 1526-6125
publication_status: published
publisher: Elsevier BV
quality_controlled: '1'
status: public
title: Process window expansion with transferable applicability in three-layer dissimilar
steel resistance spot welding via expulsion prevention
type: journal_article
user_id: '65085'
volume: 157
year: '2026'
...