Forming-limit diagrams of aluminum tailor-welded blank weld material

R. W. Davies, G. J. Grant, H. Eddie Oliver, M. A. Khaleel, M. T. Smith

Research output: Contribution to journalArticle

52 Citations (Scopus)


The current work develops forming-limit diagrams (FLDs) for weld materials in aluminum tailor-welded blanks (TWBs) under biaxial stretching conditions. Aluminum TWBs consist of multiple-thickness and alloy sheet materials welded together into a single, variable-thickness blank. The manufacture of TWBs and their application in automotive body panels requires their constituent weld material to deform under biaxial loading during sheet-metal stamping. The weld geometry is typically nonuniform and relatively small, causing difficulty if one attempts to determine the weld metal FLDs via traditional experimental methods. The subject work primarily relies on theoretical FLD calculation techniques using the Marciniak and Kuczynski (M-K) method. This numerical technique requires the use of material constants and levels of initial material imperfection that have been experimentally determined using unique miniature tensile specimens to isolate and characterize the weld metal. The experimental and numerical work, together with statistical analysis of the level of initial imperfection, allows generation of both an average and safe FLD. The weld metals studied in this work were produced via autogeneous gas tungsten arc welding of a 1- to 2-mm-thick 5000 series aluminum alloy sheet.

Original languageEnglish
Pages (from-to)275-283
Number of pages9
JournalMetallurgical and Materials Transactions A: Physical Metallurgy and Materials Science
Issue number2
Publication statusPublished - 1 Feb 2001
Externally publishedYes


ASJC Scopus subject areas

  • Materials Science(all)
  • Metals and Alloys

Cite this

Davies, R. W., Grant, G. J., Eddie Oliver, H., Khaleel, M. A., & Smith, M. T. (2001). Forming-limit diagrams of aluminum tailor-welded blank weld material. Metallurgical and Materials Transactions A: Physical Metallurgy and Materials Science, 32(2), 275-283.