Benchmarking strength and fatigue properties of spot impact welds

Kapil, Angshuman; Lee, Taeseon; Vivek, Anupam; Bockbrader, John; Abke, Tim; Daehn, Glenn S.

doi:10.1016/j.jmatprotec.2017.12.012

Cited by 38 publications

(19 citation statements)

References 19 publications

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“…SPR is currently one of the most common ways of joining dissimilar metals in the automotive industry, for its ease of automation and versatile applications [12]. The test was repeated three times for both methods, and However, nugget failure also indicates existence of a HAZ which is softer than the nugget or the base metal [9] or excessive residual stress around the nugget. the defect free fusion zone and corona bond that surround the void (cracks) can bear more load than the HAZ [15].…”

Section: Resultsmentioning

confidence: 99%

“…1. The design and geometry of the rivets used for resistance element welding of (a) aluminum and steel [8] (b) magnesium and steel [9] reported in the literature. Both studies report nugget pullout failure mode.…”

Section: Experimental Methodsmentioning

confidence: 99%

“…In particular, arc welding and resistance spot welding (RSW), the two techniques that are most commonly used in the automotive industry, have not shown to satisfy the required mechanical properties of structural applications. Lately, a number of other novel dissimilar welding technologies have been developed [7,9], but a reduced cycle time in those methods is necessary for industry implementation. To overcome such issues mechanical joints or fasteners such as self-piercing rivets (SPR) and clinching are used, but their applications are limited due to the thicknesses of the joining materials.…”

Section: Introductionmentioning

confidence: 99%

See 2 more Smart Citations

Mechanical Performance and Microstructure of Resistance Element Welds of Dissimilar Metals Created with a Headless Rivet

Oh¹,

Ryu²,

Kim³

et al. 2019

Korean J. Met. Mater.

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Resistance Element Welding (REW) is a novel processing technology developed to join dissimilar materials such as aluminum and steel. It uses an auxiliary steel rivet (element) inserted into an aluminum sheet that forms a resistance spot weld with the steel sheet, and the aluminum work piece is mechanically joined by the interlocking rivet. The versatility and agility of REW is advantageous, especially in the automotive industry. However, the head of the rivet often extends out externally over the work piece, and the misalignment of the electrode with the head can be problematic since inserting the head and the weld are performed in separate stages. In the present paper, we performed REW using a headless rivet which has minimal to no overhanging part above the aluminum surface. The lap-shear strength of REW is higher than self-piercing rivets, which makes REW a promising solution for extending applications of multi-material structures. The microstructure of the joint involves a fusion zone which mainly consists of martensite, and the failure occurs near the heat affected zone. This study finds that the electrode-rivet alignment needs to be optimized to manage the optimal nugget size and to avoid current arcing through the aluminum work piece.

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Section: Resultsmentioning

confidence: 99%

Section: Experimental Methodsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Mechanical Performance and Microstructure of Resistance Element Welds of Dissimilar Metals Created with a Headless Rivet

Oh¹,

Ryu²,

Kim³

et al. 2019

Korean J. Met. Mater.

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“…Many automakers prefer welding processes that are more productive and economical, so it is necessary to consider simpler methods than hybrid welding that consists of two processes or riveting that requires additional elements. Thus, research on solid-state welding processes such as electromagnetic pulse welding or vaporizing foil actuator welding (VFAW) is being considered as an alternative 6) . Magnetic pulse welding (MPW) [7][8][9][10][11] is a process that uses the same physical principles of explosive welding (EXW); a flyer material is rapidly driven towards a target to cause an impact, so that the surface oxides are removed by jetting 12) .…”

Section: Microstructure Evaluation Of Vaporizing Foil Actuator Welds mentioning

confidence: 99%

“…Kapil et al 6) reported that JSC590R was spot welded by VFAW. VFAW is relatively a new processing technology that uses similar physical principles of MPW, but the pressure is created by the vaporization of a thin conductor instead of an electromagnetic force.…”

Section: Microstructure Evaluation Of Vaporizing Foil Actuator Welds mentioning

confidence: 99%

Microstructure Evaluation of Vaporizing Foil Actuator Welds of 1 GPa Strength Steel

Yoon

Lee

2020

Journal of Welding and Joining

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Demands for weight reduction in automobiles have been constantly increasing due to its environmental impact, leading to increased interests in light metals such as aluminum and magnesium. However, for most structural applications that require large energy absorption, implementation of high strength steel is still a pervasive solution. When the high strength steel having a high martensite fraction (DP 980) is joined by resistance spot welding, a softening zone is generated in the welds, leading to the reduction of the strength of the welds. In addition, high strength steels generally contain a large amount of carbon and alloying elements. As a result, the carbon equivalent exhibiting hardenability increases, having the welded part become weak, and making it difficult to secure the performance required by the part or the vehicle body. Vaporizing foil actuator welding (VFAW) which is one of the solid-state welding techniques utilizes a high-pressure pulse generated by the vaporization of an aluminum foil to cause high speed collision of flyer and target sheets to create solid-state bonds with negligible melting at the weld interface. So, VFAW produces joints with little to no HAZ. In this study, to examine the vaporizing foil actuator welding properties of 1 GPa grade high strength steel, microstructure analysis and hardness test were performed. The test results were compared with the resistance spot welding properties of the same material.

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Recent Developments of Vaporizing Foil Actuator Technique for Manufacturing Applications

Prasad

Barnett

et al. 2021

Forming the Future

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Benchmarking strength and fatigue properties of spot impact welds

Cited by 38 publications

References 19 publications

Mechanical Performance and Microstructure of Resistance Element Welds of Dissimilar Metals Created with a Headless Rivet

Mechanical Performance and Microstructure of Resistance Element Welds of Dissimilar Metals Created with a Headless Rivet

Microstructure Evaluation of Vaporizing Foil Actuator Welds of 1 GPa Strength Steel

Recent Developments of Vaporizing Foil Actuator Technique for Manufacturing Applications

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