Effects of failure modes on strength of aluminum resistance spot welds

Xin Sun, Elizabeth Stephens, Rich Davies, Moe Khaleel, Donald J. Spinella

Research output: Chapter in Book/Report/Conference proceedingConference contribution

5 Citations (Scopus)


This paper examines the effects of failure modes on the static strength and total energy absorption of aluminum spot-welded samples using experimental, statistical, and analytical approaches. The main failure modes for aluminum spot welds are nugget pullout and interfacial fracture. Two populations of aluminum spot welds were studied. Within each population, coupon configurations of lap shear, cross tension and coach peel were considered. Thirty replicate static strength tests were performed for each coupon configuration. The resulted peak load and energy absorption level associated with each failure mode was studied using statistical models. Next, an analytical model was developed to determine the failure mode of an aluminum resistance spot weld based on stress analysis. It is found that weld size, sheet thickness, and level of weld porosity and defects are the main factors determining the cross tension failure mode for an aluminum spot weld. The peak load and energy absorption levels for the cross tension and coach peel samples tested are found not to be very sensitive to the failure modes under static loading.

Original languageEnglish
Title of host publicationSAE Technical Papers
Publication statusPublished - 1 Dec 2005
Externally publishedYes
Event2005 SAE World Congress - Detroit, MI, United States
Duration: 11 Apr 200514 Apr 2005


Other2005 SAE World Congress
CountryUnited States
CityDetroit, MI


ASJC Scopus subject areas

  • Automotive Engineering
  • Safety, Risk, Reliability and Quality
  • Pollution
  • Industrial and Manufacturing Engineering

Cite this

Sun, X., Stephens, E., Davies, R., Khaleel, M., & Spinella, D. J. (2005). Effects of failure modes on strength of aluminum resistance spot welds. In SAE Technical Papers https://doi.org/10.4271/2005-01-0906