On Residual Stresses in Resistance Spot-Welded Aluminum Alloy 6061-T6: Experimental and Numerical Analysis

Afshari, Davood; Sedighi, M.; Karimi, Mahmoud; Barsoum, Zuheir

doi:10.1007/s11665-013-0657-1

Cited by 12 publications

(9 citation statements)

References 9 publications

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“…Shen et al [14] verified results of 3-sheet joints of combinations of DP600 and mild steel and reported that the model somewhat underestimated weld sizes in all interfaces. In addition, Afshari et al [15] made comparative studies of 6061 aluminum alloy welds with good agreement between simulations and experiments.…”

Section: Introductionmentioning

confidence: 93%

Prediction and Verification of Resistance Spot Welding Results of Ultra-High Strength Steels through FE Simulations

Andersson

Melander²

2015

MNSMS

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Resistance spot welding (RSW) is the most common welding method in automotive engineering due to its low cost and high ability of automation. However, physical weldability testing is costly, time consuming and dependent of supplies of material and equipment. Finite Element (FE) simulations have been utilized to understand, verify and optimize manufacturing processes more efficiently. The present work aims to verify the capability of FE models for the RSW process by comparing simulation results to physical experiments for materials used in automotive production, with yield strengths from approximately 280 MPa to more than 1500 MPa. Previous research has mainly focused on lower strength materials. The physical weld results were assessed using destructive testing and an analysis of expulsion limits was also carried out. Extensive new determination of material data was carried out. The material data analysis was based on physical testing of material specimens, material simulation and comparison to data from literature. The study showed good agreement between simulations and physical testing. The mean absolute error of weld nugget size was 0.68 mm and the mean absolute error of expulsion limit was 1.10 kA.

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Section: Introductionmentioning

confidence: 93%

Prediction and Verification of Resistance Spot Welding Results of Ultra-High Strength Steels through FE Simulations

Andersson

Melander²

2015

MNSMS

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“…Florea et al 8) The work revealed that the welding process parameters have a great influence in the microstructure and fatigue life and different fatigue failure modes were observed at several load ranges and ratios for a constant frequency and three welding currents. In the study of D. Afshari et al 9) an electro-thermal-structural-coupled finite element model and x-ray diffraction residual stress measurements have been utilized to analyze distribution of residual stresses in an aluminum alloy 6061-T6 resistance spot-welded joint with 2-mm-thickness sheet. The results have a good agreement with experimental data obtained from x-ray diffraction residual stress measurements.…”

Section: Introductionmentioning

confidence: 99%

Microstructure and Mechanical Properties of Laser Welded Al–Mg–Si Alloy Joints

Yang

Duan

et al. 2019

Mater. Trans.

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In this paper, AlMgSi alloy with the thickness of 2.5 mm was overlap welded by fiber laser. Optical microscopy, scanning electron microscopy, energy dispersive spectroscopy, hardness tester, and electro-hydraulic servo testing machine were used for the microstructure observation and mechanical property examination. Specimens extracted from the welded plates were tested at room temperature for the determination of the tensile and fatigue properties of the welded joints. Results showed the columnar grains were formed in the fusion boundary, while equiaxed grains were formed in the fusion zone; the lowest hardness in the fusion zone is 72.0 HV, gradually increasing from the heataffected zone to the BM. Tensile shear strength of the welded joint is 96.0 Mpa, which is about 25% of the tensile strength of base metal. The fatigue limit at 1 © 10 6 conditional cycles is 22.5 MPa. The fractography showed intergranular and quasi-cleavage fracture. Bending deformation is related to the magnitude of the force. As the stress lower, the deformation become more severe.

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“…They, in another study on fatigue life of RSW of 6061-T6 aluminum alloy, realized that welding parameters had great influence on life and fatigue fracture model. 13 Afshari et al 14 studied the residual stresses in resistance spot welded aluminum alloy 6061-T6 by using experimental and numerical approaches. Wang et al 15 simulated Al-steel RSW process by developing a fully coupled multi-physics model.…”

Section: Introductionmentioning

confidence: 99%

Investigation of the effect of sheet thickness on residual stresses in resistance spot welding of aluminum sheets

Sedighi

Afshari

Nazari

2016

Proceedings of the Institution of Mechanical Engineers, Part C:

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The main purpose of this study is to investigate the effect of sheet thickness on nugget size and residual stresses in resistance spot welding. A two-dimensional coupled electro-thermo-mechanical finite element model is employed to predict the residual stresses in aluminum alloy 6061-T6. The simulation results are compared with the results obtained from the experimental nugget size and the residual stresses are measured by the X-ray diffraction method. The results indicate that the highest tensile residual stress occurs at the center of the nugget and diminish along the nugget radius. The residual stresses increase on increasing the electrical current and reducing the welding time. By increasing the sheet thickness, the affordable range of welding current and welding cycle increase. It also leads to the enlargement of the nugget, which consequently results in the increase of the residual stresses.

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On Residual Stresses in Resistance Spot-Welded Aluminum Alloy 6061-T6: Experimental and Numerical Analysis

Cited by 12 publications

References 9 publications

Prediction and Verification of Resistance Spot Welding Results of Ultra-High Strength Steels through FE Simulations

Prediction and Verification of Resistance Spot Welding Results of Ultra-High Strength Steels through FE Simulations

Microstructure and Mechanical Properties of Laser Welded Al–Mg–Si Alloy Joints

Investigation of the effect of sheet thickness on residual stresses in resistance spot welding of aluminum sheets

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