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<p>Patchwork blanks hot stamping technology can manufacture automobile parts with lightweight and high strength, which are increasingly being used in automobile body parts manufacturing. Since the patched blank needs to be spot welded to the main blank before forming, the arrangement of welding spots significantly affects the formability of the parts. The number of welding spots, welding spot diameter, and thickness ratio between the main blank and patched blank were chosen as the input variables. A welding spot arrangement program was developed based on the conditional distribution algorithm. The response surface method was used to analyze the influence of these variables on formability, and genetic algorithm was applied for optimization. The results showed that excessive welding spots could cause stress concentrations that might lead to crack during hot stamping. Too large welding spots diameter enlarged the heat-affected zone and degraded the formability of the material. To balance the lightweight and formability of the part, it is recommended that the thickness of the main blank is between 0.75 and 1.0 times that of the patched blank. The optimal configuration for the A-pillar patched blank was 16 spots with a diameter of 6.7&#xa0;mm, maintaining a thickness ratio of 0.81 between the main blank and patched blank, which achieved a balance between formability and structural performance.</p>

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Research on Optimization of Welding Spots Arrangement for A-Pillar Patched Blanks

  • 期刊论文

  • 发表日期：

    2026年5月8日

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  • Wenfeng Li,
  • Zhiqiang Zhang,
  • Ruoting Wang,
  • Hongjie Jia,
  • Mingwen Ren,
  • Huihui Yang

摘要

Patchwork blanks hot stamping technology can manufacture automobile parts with lightweight and high strength, which are increasingly being used in automobile body parts manufacturing. Since the patched blank needs to be spot welded to the main blank before forming, the arrangement of welding spots significantly affects the formability of the parts. The number of welding spots, welding spot diameter, and thickness ratio between the main blank and patched blank were chosen as the input variables. A welding spot arrangement program was developed based on the conditional distribution algorithm. The response surface method was used to analyze the influence of these variables on formability, and genetic algorithm was applied for optimization. The results showed that excessive welding spots could cause stress concentrations that might lead to crack during hot stamping. Too large welding spots diameter enlarged the heat-affected zone and degraded the formability of the material. To balance the lightweight and formability of the part, it is recommended that the thickness of the main blank is between 0.75 and 1.0 times that of the patched blank. The optimal configuration for the A-pillar patched blank was 16 spots with a diameter of 6.7 mm, maintaining a thickness ratio of 0.81 between the main blank and patched blank, which achieved a balance between formability and structural performance.