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By increasing the electrode force, it would be an alternative way to avoid weld expulsion in resistance spot welding (RSW) of dual phase (DP) steel with initial gap. To investigate the influence of the electrode force on weld expulsion, a weld expulsion estimation method based on a finite element model were used to analyze the contact state, electrical field, temperature distribution and weld nugget formation process. The simulation results were validated by the experiments. It was shown that adoi:10.2355/isijinternational.52.493 fatcat:n47qmzv5p5dwte553w5yprstai