Role of weld nugget size at Al/steel and steel/steel interface in fatigue behavior of three-sheet Al-steel-steel dissimilar resistance spot welds

IF 4.4 2区工程技术 Q1 ENGINEERING, MECHANICAL

Engineering Failure Analysis Pub Date : 2025-04-07 DOI:10.1016/j.engfailanal.2025.109589

Liting Shi , Blair E. Carlson , Guanyou Li , Hassan Ghassemi-Armaki

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引用次数: 0

Abstract

Resistance Spot Welding (RSW) has been effectively applied to join aluminum alloys with steel. However, welding aluminum alloys to advanced high-strength steels (AHSS), which are widely used in automotive structures, remains a challenge. This study utilized a high-strength low-alloy (HSLA) or low-carbon steel (LCS) sheet as an intermediate layer between aluminum and AHSS to create three-layer Al-steel-steel RSWs. The resulting welds exhibited large nugget diameters in both aluminum and steel, along with the formation of a thin and uniform intermetallic compound (IMC) at the aluminum-steel interface. The joint strength and fatigue performance of the three-sheet aluminum-to-steel welds were comparable to those of two-sheet welds. However, the fatigue life data did not converge to a single master curve using structural stress analysis, indicating that the diameter of the aluminum weld nugget is not the only factor influencing fatigue performance. Conversely, the steel weld nugget size significantly affected joint stiffness and fatigue life. By adopting the maximum principal strain approach, all fatigue data collapsed onto one master curve, suggesting it as a more reliable parameter for predicting fatigue life in three-sheet RSW configurations.

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铝/钢和钢/钢界面熔核尺寸对三片铝-钢异种电阻点焊疲劳行为的影响

电阻点焊（RSW）已被有效地应用于铝合金与钢的连接。然而，将铝合金焊接到广泛应用于汽车结构的先进高强度钢（AHSS）上仍然是一个挑战。本研究利用高强度低合金（HSLA）或低碳钢（LCS）板材作为铝和AHSS之间的中间层，制造了三层al -钢-钢RSWs。结果表明，铝和钢的焊缝均具有较大的熔核直径，并在铝-钢界面处形成了薄而均匀的金属间化合物（IMC）。三层铝-钢焊缝的接头强度和疲劳性能与两层铝-钢焊缝相当。然而，利用结构应力分析得到的疲劳寿命数据并没有收敛到单一的主曲线，这表明铝焊核直径并不是影响疲劳性能的唯一因素。相反，焊核尺寸对接头刚度和疲劳寿命有显著影响。通过采用最大主应变法，所有的疲劳数据都集中在一条主曲线上，这表明它是预测三层RSW结构疲劳寿命的更可靠的参数。

本文章由计算机程序翻译，如有差异，请以英文原文为准。

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来源期刊

Engineering Failure Analysis 工程技术-材料科学：表征与测试

CiteScore

7.70

自引率

20.00%

发文量

956

审稿时长

47 days

期刊介绍： Engineering Failure Analysis publishes research papers describing the analysis of engineering failures and related studies. Papers relating to the structure, properties and behaviour of engineering materials are encouraged, particularly those which also involve the detailed application of materials parameters to problems in engineering structures, components and design. In addition to the area of materials engineering, the interacting fields of mechanical, manufacturing, aeronautical, civil, chemical, corrosion and design engineering are considered relevant. Activity should be directed at analysing engineering failures and carrying out research to help reduce the incidences of failures and to extend the operating horizons of engineering materials. Emphasis is placed on the mechanical properties of materials and their behaviour when influenced by structure, process and environment. Metallic, polymeric, ceramic and natural materials are all included and the application of these materials to real engineering situations should be emphasised. The use of a case-study based approach is also encouraged. Engineering Failure Analysis provides essential reference material and critical feedback into the design process thereby contributing to the prevention of engineering failures in the future. All submissions will be subject to peer review from leading experts in the field.