Competing fracture modes in Al-steel resistance spot welded structures: Experimental evaluation and numerical prediction

Qian, Cheng; Ghassemi-Armaki, Hassan; Shi, Liting; Kang, Jidong; Haselhuhn, Amberlee S.; Carlson, Blair E.

doi:10.1016/j.ijimpeng.2023.104838

Cited by 9 publications

(2 citation statements)

References 33 publications

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“…The melted metal begins to shrink considerably at this stage, so it is necessary to continue applying pressure by the electrode to form a denser welded joint. The method has the advantages of short heating time, small material deformation, low production cost and easy automation, which does not require other fill materials to form joints [10][11][12][13]. At the same time, RSW can not only weld steel materials but can also weld aluminum, copper and other non-ferrous metals and alloys, which is the most common Metals 2024, 14, 429 2 of 14 pressure welding method with a wide range of applications [14][15][16][17].…”

Section: Introductionmentioning

confidence: 99%

Effects of Interlayer on the Microstructure and Mechanical Properties of Resistance Spot Welded Titanium/Steel Joints: A Short Review

Liu,

Zhang

2024

Metals

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In this paper, the influence of interlayer on titanium/steel dissimilar metal resistance spot welding is reviewed from the aspects of macroscopic characteristics, microstructure and interface bonding properties of the joint. Previous studies have demonstrated that TiC, FeTi and Fe2Ti intermetallic compounds with high brittleness are formed in the joint during titanium/steel welding, which reduces the strength of the welded joint. Researchers proposed different interlayer materials, including Cu, Ni, Nb, Ta, 60%Ni-Cu alloy and BAg45CuZn. Firstly, adding an interlayer can weaken the diffusion of Fe and Ti. Secondly, the interlayer elements can combine with Fe or Ti to form solid solutions or intermetallic compounds with lower brittleness than Fe–Ti compounds. Finally, Cu, Ni, Ag, etc. with excellent ductility can effectively decrease the generation of internal stress, which reduces the formation of defects to improve the strength of the joint.

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Section: Introductionmentioning

confidence: 99%

Effects of Interlayer on the Microstructure and Mechanical Properties of Resistance Spot Welded Titanium/Steel Joints: A Short Review

Liu,

Zhang

2024

Metals

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“…The high tensile and fatigue properties of the Al alloy/steel joints can be achieved by using the optimized RSW joining technique [ 8 , 9 , 10 ]. However, the Al alloy/steel RSW joint is still susceptible to corrosion and joint strength degradation in an aggressive environment due to the complicated microstructure and intrinsic differences in the electrochemical corrosion properties at the joint interface [ 11 , 12 ]. Therefore, the corrosion behavior must be understood to ensure the reliable employment of the Al alloy/steel RSW technique.…”

Section: Introductionmentioning

confidence: 99%

Corrosion Behavior and Mechanical Property of 5182 Aluminum/DP780 Steel Resistance Spot Welding Joints

Shi,

Zhang,

et al. 2024

Materials

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Corrosion behavior is critical to the application of lightweight aluminum/steel joints using new resistance spot welding (RSW) technology. The study investigated the corrosion mechanism and the shear strength of RSW joints comprising 1.2 mm 5182 aluminum and 1.5 mm DP780 galvanized steel. Electrochemical corrosion tests were conducted on the base materials and various positions of the welds in a 3.5% NaCl solution. This result revealed that the corrosion susceptibility of the interfacial intermetallic compound (IMC) layer was not accelerated by the aluminum nugget because of the noble corrosion potential. Subsequently, the spray acceleration test was employed to investigate the corrosion mechanism. It is noteworthy that microcracks, as well as regions enriched with silicon and oxygen at the interface front, are preferential to corrosion during salt spray exposure, instead of the IMC layer. Moreover, the shear strength of the joints decreases with the reduction in the effective joint area after the salt spray exposure of the weld joints. This research systematically explored the corrosion behavior and its relationship with the mechanical properties of Al alloy/steel RSW joints.

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Real‐Time Observation of Strain Evolution in Lap Shear Test of BH220 Steel Resistance Spot‐Welded Joints via a Digital Image Correlation Method

Zhao,

Guseinov,

Vdonin

et al. 2024

steel research int.

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This article presents an investigation of the real‐time deformation and strain field changes of baked hardening (BH) 220 steel plate resistance spot welds in the lap tensile shear tests via digital image correlation (DIC) technology. 2D DIC analysis can be used to provide a quantitative assessment of the strain competition between the weld nugget and the surrounding metal. The data obtained from the DIC technique indicate that the shear strain is primarily concentrated in the outer metal of the weld, consistent with a nugget pull‐out failure (PF) mode. In contrast, if the welding parameters are inappropriate, for example, if the welding current is 7.2 kA, the welding time is 10 cycles and the electrode pressure is 0.35 MPa, a significant shear strain appears in the nugget of the BH220 weld. This subsequently causes the weld to fail in an unfavorable interface failure mode in the shear test. Calculations show that if the failure mode is nugget pull‐out, the mean failure strength is 13.5 kN, while the value for interface failure is 6.55 kN. The PF mode is characterized by ductile failure, whereby the material yields and necks through the base material. This failure mode is not associated with the notch region.

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Competing fracture modes in Al-steel resistance spot welded structures: Experimental evaluation and numerical prediction

Cited by 9 publications

References 33 publications

Effects of Interlayer on the Microstructure and Mechanical Properties of Resistance Spot Welded Titanium/Steel Joints: A Short Review

Effects of Interlayer on the Microstructure and Mechanical Properties of Resistance Spot Welded Titanium/Steel Joints: A Short Review

Corrosion Behavior and Mechanical Property of 5182 Aluminum/DP780 Steel Resistance Spot Welding Joints

Real‐Time Observation of Strain Evolution in Lap Shear Test of BH220 Steel Resistance Spot‐Welded Joints via a Digital Image Correlation Method

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