Typical vehicles contain more than 3000 spot welds, and failure parameters for these welds must be accurately predicted in crash simulations. A testing protocol developed at EWI for the purpose of creating spot weld failure parameters has been used since 2010 to establish these parameters for automotive manufacturers for a range of steel and aluminum stack-ups. Crash simulations in full-vehicle models show that the failure parameters created by this method are accurate for predicting the initiation of spot weld failure by comparing results with experimental data.

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