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An axisymmetric finite element model employing coupled thermal–electrical–mechanical analysis of resistance spot welding is presented. The welding parameters considered include: heat generation at the faying surface and the workpiece–electrode surface; Joule heating at the workpiece and the electrode; and the thermal contact conductance between the electrode and the workpiece. The latent heat of phase change due to melting is accounted for. The effect of friction coefficient on the workpiece interface is also studied. The computed results agree well with the experimental data. Heat generation at the faying surface in the initial stages of welding dominates the nugget development, and Joule heating at long times governs the weld nugget growth. A parametric study is carried out for the nugget growth with specific consideration of resistance spot welding of Al alloys. Process control and modelling of resistance …