A computational model is presented in this article for the prediction of microstructural development during heat treating of steels and resultant room-temperature hardness. This model was applied in this study to predict the hardness distribution in end-quench bars (Jominy hardness) of heat treatable steels. It consists of a thermodynamics model for the computation of equilibria in multicomponent Fe-C-M systems, a finite element model to simulate the heat transfer induced by end quenching of Jominy bars, and a reaction kinetics model for austenite decomposition. The overall methodology used in this study was similar to the one in the original work of Kirkaldy. Significant efforts were made to reconstitute the reaction kinetics model for austenite decomposition in order to better correlate the phase transformation theory with empiricism and to allow correct phase transformation predictions under continuous cooling conditions. The present model also expanded the applicable chemical composition range. The predictions given by the present model were found to be in good agreement with experimental measurements and showed considerable improvement over the original model developed by Kirkaldy et al.

Resistance spot welding is one of the major Joining methods widely used in automotive body fabrication and assembly. Electrode wear has been a major concern in resistance spot welding of galvanised steel and in this paper advanced finite element techniques were used to simulate the thermomechanical interactions between the electrode and the workpiece during welding. First, the coupled electric–thermal–mechanical process associated with nugget formation was studied. The cumulative effects on electrode face deformation were then simulated over a large number of welds. Electrode face pitting effects were also examined. It was found that welding process parameters, such as holding time and pressure trace, played a key role in electrode face extrusion. Any pitting on the electrode tended to accelerate the face extrusion process.

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