The interactive effect of microstructure and stress state on the microscopic damage development of aluminum alloy tailor-welded blank

Xing, Lei; Zhan, Mei; Gao, Pengfei; Li, M.; Dong, Yongpeng; He, Wei

doi:10.1016/j.matdes.2020.108836

Cited by 12 publications

(4 citation statements)

References 35 publications

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“…One of the main tasks is to accurately predict the plastic, damage, and fracture behavior. In the last decades, a large body of literature has indicated that the damage and fracture behavior depends on the stress states [1][2][3][4][5][6]. However, most researchers focus on monotonic or uniaxial cyclic loading conditions [7][8][9][10][11][12][13].…”

Section: Introductionmentioning

confidence: 99%

Mechanical Responses of Ductile Aluminum Alloy under Biaxial Non-Proportional Tensile Reverse Loading Patterns

Wei,

Gerke,

Brünig

2023

Metals

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This paper deals with the study of the mechanical responses of ductile metals under biaxial non-proportional cyclic loading tests. The biaxially loaded HC specimens manufactured from 4 mm thick aluminum alloy sheets (EN AW 6082-T6) are subjected to various loading paths, including monotonic and cyclic loading conditions. The aim is to investigate the plastic, damage, and fracture behavior of the material under these different loading scenarios. In terms of numerical aspects, a modified anisotropic two-surface cyclic plastic–damage continuum model is used to predict the material behavior in the load-displacement field and different strain fields. Numerically predicted stress states are analyzed in detail to gain a better understanding of the damage mechanisms. Moreover, the scanning electronic microscopy (SEM) pictures taken from the fracture surfaces confirm the dependency of the damage mechanisms on the loading histories. The present work indicates the importance of considering different loading conditions for the accurate prediction of material responses.

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Section: Introductionmentioning

confidence: 99%

Mechanical Responses of Ductile Aluminum Alloy under Biaxial Non-Proportional Tensile Reverse Loading Patterns

Wei,

Gerke,

Brünig

2023

Metals

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“…Fatigue failure is one of the main reasons for the failure of axle housing, which bears alternating loads for a long time 2 . The fatigue life of weld mainly determine the fatigue life of welded axle housing 3,4 …”

Section: Introductionmentioning

confidence: 99%

“…2 The fatigue life of weld mainly determine the fatigue life of welded axle housing. 3,4 At present, the fatigue life calculation of welded structures is mainly based on nominal stress or hot-spot stress method and a series of classified welding S-N curves, [5][6][7][8][9][10] although the fatigue life method based on local stress [11][12][13] provides an alternative method. The results are often problematic because these stresses can be strongly dependent on mesh size and loading patterns.…”

Section: Introductionmentioning

confidence: 99%

Research on fatigue reliability prediction model and structural improvement of welded drive axle housing based on master S‐N Curve method

Tan

Wang

Xie

et al. 2022

Quality & Reliability Eng

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Fatigue reliability prediction of welded structures is mainly based on nominal stress or hot spot stress method, but there are some problems such as grid sensitivity and joint geometry dependence. The Master S-N curve method can solve these problems well, but the corresponding reliability model needs to be studied. In this paper, the fatigue reliability model of welded structures based on the Master S-N curve method is studied. Considering the randomness of life and the correlation of failure, a reliability model is proposed, which reduces the computational burden by establishing a median damage-random threshold rule. Taking the welded drive axle housing as an object, the system reliability is analyzed under the bench test condition, and verified by the experimental data. After the verification, this method is used to predict the reliability of the axle housing under variable amplitude loading collected in the test field, and the results are verified by Monte Carlo (MC) method. When the P-S-N curves are parallel, the model is accurate, which is the characteristic of the Master S-N curve method. This method only needs to input the median damage value of the weak part, which is easy to be applied. This method can speed up the reliability prediction cycle of welded structures, which is beneficial to product innovation and optimal design. Finally, an improved design scheme is proposed for the weak parts of welding, and the effects of welding leg width, welding depth, and closed weld on fatigue life are revealed.

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“…In addition to that, Karthikeyan et al (2010) and Maji (2019) has found that the strength of sheet material reduces when subjected to welding owing due to the variations in their microstructure. This has led to development of tailor welded blanks (TWB) which optimizes the material thickness, improves the crash behaviour and reduces the overall component weight in automobiles (Xing et al 2020).…”

mentioning

confidence: 99%

Forming of Tailor-Welded Blanks Through Centerline and Offset Laser Welding

Mayavan¹,

Karthikeyan²,

Balamugundan³

et al. 2022

International Journal of Manufacturing, Materials, and Mechanical Engineering

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The forming of low and high strength tailor welded steel sheets into preferred three-dimensional shapes by a homogeneous distribution of plastic strain is highly difficult. In this work, the formability of tailor-welded blanks prepared using laser welding of low (IS 513 CR2, IS 513 CR3) and high tensile strength (AISI 304) steel sheets were analyzed and the formation of the edge profile and weld line movement was also examined. The results showed a decrease in formability characteristics owing to the increase in Strength Ratio. Scanning Electron Microscope analysis of the fracture locations within unsuccessfully formed tailor welded blanks showed the presence of tempered martensite in the soft zone was found to be the most predominant factor affecting its failure. The formability characteristics of investigated tailored blanks were predicted using finite element simulation and compared with experimented results for validation.

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The interactive effect of microstructure and stress state on the microscopic damage development of aluminum alloy tailor-welded blank

Cited by 12 publications

References 35 publications

Mechanical Responses of Ductile Aluminum Alloy under Biaxial Non-Proportional Tensile Reverse Loading Patterns

Mechanical Responses of Ductile Aluminum Alloy under Biaxial Non-Proportional Tensile Reverse Loading Patterns

Research on fatigue reliability prediction model and structural improvement of welded drive axle housing based on master S‐N Curve method

Forming of Tailor-Welded Blanks Through Centerline and Offset Laser Welding

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