In adhesive‐assisted resistance spot welding, the amount of adhesive remaining under the electrodes after squeeze‐out can significantly affect the local contact state and process stability. However, the quantity of residual adhesive is often not considered because it requires high‐resolution characterization of a small, locally confined surface region together with a consistent definition of the electrode force application area. Reliable, data‐driven quantification is also relevant for monitoring and correlating the process parameters with resulting joint behavior, but evaluation is frequently limited to nonstandardized postprocessing, which reduces comparability across experiments. This work presents an experimental‐to‐digital evaluation chain in which chromatic confocal surface measurements are processed using an OpenCV‐based method to automatically detect the electrode imprint and to quantify residual adhesive volume within the corresponding contact region. The acquired surface‐height dataset is calibrated and evaluated by numerical height integration inside a geometry‐consistent integration domain derived from the detected imprint. By implementing the analysis as a parameterized pyiron workflow, the procedure becomes a traceable data‐processing pipeline with standardized configuration, automated batch execution, and structured storage of results and metadata, allowing the extracted adhesive metrics to be reused directly in downstream statistical evaluation, reporting, and simulation‐oriented analyses.
Wi et al. (Tue,) studied this question.