Abstract: “Tailor-welded blanks (TWBs) are primarily used in the automotive industry. Popular applications include: side frames, doors, pillars and rails. The TWB concept has several disadvantages. The most important disadvantage is the effect of the weld line on the formability of the TWB. This paper investigates the weldment quality by evaluating the localized stresses, strains and distortions that develop during welding. For the purpose of investigation, TWBs made of 304 stainless steel and A619 low carbon steel have been numerically simulated using a finite volume formulation. Blanks with different configurations (blank sizes, thicknesses and weldment type) have been simulated, so that the optimal processing parameters for each configuration can be determined. Conclusion about the scaling effect and the residual stresses in the welded blanks could be drawn based upon the evaluation of the different configurations”

Keywords: TWB, Scaling effect, Numerical simulation, Finite volume, GMAW, Dissimilar materials, Failure prediction