This open-source tool provides a 3D visualization of the welding process window (Lobe) for automotive steel grades. It utilizes the Asari-Rashidi Nugget Growth Model to predict the relationship between Current, Time, and Force across 2-ply and 3-ply metal stacks.
The app specifically addresses modern automotive challenges, such as:
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Dissimilar Material Stacks: Calculating heat generation when mixing Mild Steel with Ultra-High-Strength Steel (UHSS).
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3-Ply Combinations: Providing flexibility for complex assembly joins (with an optional 3rd layer).
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Weldability Safety: Real-time Carbon Equivalent (CE) monitoring to prevent brittle weld failures.
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Dynamic Material Library: Includes standard grades like JSC270, DP600, DP980, and Boron Steel (Usibor 1500).
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2-Ply & 3-Ply Modes: Select "NIL" for the third layer to revert to a standard 2-sheet calculation.
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Physics-Based Calculations:
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Weighted k-Factor: Adjusts heat generation based on the resistivity and thickness of each ply in the stack.
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Zinc Coating Factor: Automatically adjusts contact resistance for GA/GI coated steels.
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Expulsion Limit: Predicts the upper boundary of the weld lobe where excessive heat causes metal splashing.
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Interactive 3D Visualization: Explore the weldable volume using a Plotly-powered isosurface.
To run this project locally, ensure you have Python installed, then follow these steps:
- Clone the repository:
git clone https://github.com/your-username/asari-rashidi-3d-lobe.git
cd asari-rashidi-3d-lobe
- Install dependencies:
pip install -r requirements.txt
- Run the app:
streamlit run app.py
The model calculates the nugget diameter based on the energy input formula
Where is the thickness-weighted resistivity factor of the entire stack.
Distributed under the MIT License. See LICENSE for more information.
Mohd Rashidi Asari. (2026). RashidiA/Automotive-3D-Spot-Weld-Lobe-Simulator: Initial public release (v1.0.0). Zenodo. https://doi.org/10.5281/zenodo.18706989