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Title: Effects of Fusion Zone Size on Failure Modes and Performance of Advanced High Strength Steel Spot Welds (2006-01-0531)

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 pullout 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 micro-hardness 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 resulted peak load and energy absorption levels associated with each failure mode were studied using statistical data analysis tools. The results in this study show that the conventional weld size of 4 t1/2 can not produce nugget pullout 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.

Authors:
; ;
Publication Date:
Research Org.:
Pacific Northwest National Lab. (PNNL), Richland, WA (United States)
Sponsoring Org.:
USDOE
OSTI Identifier:
921408
Report Number(s):
PNNL-SA-55842
VT0502010; TRN: US200804%%801
DOE Contract Number:  
AC05-76RL01830
Resource Type:
Journal Article
Resource Relation:
Journal Name: SAE Transactions. Journal of Materials & Manufacturing, 115(Part 5):509-516; Journal Volume: 115; Journal Issue: Part 5
Country of Publication:
United States
Language:
English
Subject:
36 MATERIALS SCIENCE; CROSS SECTIONS; ENERGY ABSORPTION; FRACTURES; PEAK LOAD; PERFORMANCE; STATISTICAL DATA; STEELS; WELDED JOINTS; Advanced high strength steels; Spot Welds; Weld Fusion Zone Size; Weld Failure Mode

Citation Formats

Sun, Xin, Stephens, Elizabeth V., and Khaleel, Mohammad A. Effects of Fusion Zone Size on Failure Modes and Performance of Advanced High Strength Steel Spot Welds (2006-01-0531). United States: N. p., 2007. Web.
Sun, Xin, Stephens, Elizabeth V., & Khaleel, Mohammad A. Effects of Fusion Zone Size on Failure Modes and Performance of Advanced High Strength Steel Spot Welds (2006-01-0531). United States.
Sun, Xin, Stephens, Elizabeth V., and Khaleel, Mohammad A. Thu . "Effects of Fusion Zone Size on Failure Modes and Performance of Advanced High Strength Steel Spot Welds (2006-01-0531)". United States. doi:.
@article{osti_921408,
title = {Effects of Fusion Zone Size on Failure Modes and Performance of Advanced High Strength Steel Spot Welds (2006-01-0531)},
author = {Sun, Xin and Stephens, Elizabeth V. and Khaleel, Mohammad A.},
abstractNote = {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 pullout 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 micro-hardness 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 resulted peak load and energy absorption levels associated with each failure mode were studied using statistical data analysis tools. The results in this study show that the conventional weld size of 4 t1/2 can not produce nugget pullout 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.},
doi = {},
journal = {SAE Transactions. Journal of Materials & Manufacturing, 115(Part 5):509-516},
number = Part 5,
volume = 115,
place = {United States},
year = {Thu Mar 01 00:00:00 EST 2007},
month = {Thu Mar 01 00:00:00 EST 2007}
}