Effects of fusion zone size on failure modes and performance of advanced high strength steel spot welds

Xin Sun, Elizabeth Stephens, Moe Khaleel

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

Abstract

This paper examines the effects of fusion zone size on failure modes, static strength and energy absorption of resistance spot welds (RSW) of advanced high strength steels (AHSS). DP800 and TRIP800 spot welds are considered. The main failure modes for spot welds are nugget pull-out and interfacial fracture. Partial interfacial fracture is also observed. The critical fusion zone sizes to ensure nugget pull-out failure mode are developed for both DP800 and TRIP800 using the limit load based analytical model and the microhardness measurements of the weld cross sections. Static weld strength tests using cross-tension samples were performed on the joint populations with controlled fusion zone sizes. The resultant peak load and energy absorption levels associated with each failure mode were studied using statistical data analysis tools. The results of this study show that the conventional weld size of can not produce nugget pull-out mode for both the DP800 and TRIP800 materials. The results also suggest that performance based spot weld acceptance criteria should be developed for different AHSS spot welds.

Original languageEnglish
Title of host publicationSAE Technical Papers
DOIs
Publication statusPublished - 1 Dec 2006
Externally publishedYes
Event2006 SAE World Congress - Detroit, MI, United States
Duration: 3 Apr 20066 Apr 2006

Other

Other2006 SAE World Congress
CountryUnited States
CityDetroit, MI
Period3/4/066/4/06

Fingerprint

High strength steel
Failure modes
Welds
Fusion reactions
Energy absorption
Load limits
Microhardness
Analytical models

ASJC Scopus subject areas

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

Cite this

Effects of fusion zone size on failure modes and performance of advanced high strength steel spot welds. / Sun, Xin; Stephens, Elizabeth; Khaleel, Moe.

SAE Technical Papers. 2006.

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

Sun, X, Stephens, E & Khaleel, M 2006, Effects of fusion zone size on failure modes and performance of advanced high strength steel spot welds. in SAE Technical Papers. 2006 SAE World Congress, Detroit, MI, United States, 3/4/06. https://doi.org/10.4271/2006-01-0531
Sun, Xin ; Stephens, Elizabeth ; Khaleel, Moe. / Effects of fusion zone size on failure modes and performance of advanced high strength steel spot welds. SAE Technical Papers. 2006.
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