Numerical analysis of the effect of pore on local stresses in spot welds

► The existence of pores has a significant influence on the local stresses. ► The higher stress is located at the vicinity of the interface matrix–pore. ► It is more significant when the pores are in the vicinity very close one to other. ► Pores-defect interaction has an influence on the level of the developed stresses. In this investigation, the finite element analysis has been employed to study the distribution and the level of stress induced in a ferritic matrix by pores resulting from the process of welding. The effect of pore inter-distance and the interaction between pore and different weld imperfections in a spot weld (pore–pore, pore–precipitate and pore-micro-crack) on the stresses level were highlighted. The results showed that the distribution of the pores and the interaction between pores and different weld imperfections have a significant influence on the level of the developed stresses.