Investigation on fatigue evaluation parameter for resistance spot welding with gap defects

IF 5.6 2区工程技术 Q1 ENGINEERING, MECHANICAL

Theoretical and Applied Fracture Mechanics Pub Date : 2025-09-13 DOI:10.1016/j.tafmec.2025.105238

Yulong Su , Kai Song , Yixin Chen , Changye Liu , Qihong Fang , Hao Jin

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引用次数: 0

Abstract

Resistance spot welding (RSW) is a prevalent method for connecting thin plates in automotive body structures, directly impacting structural safety. Variations such as sheet forming rebound, assembly deviation, and manufacturing errors often result in initial gaps (IGs) between sheets prior to welding. These gaps can exacerbate uneven plastic deformation, leading to warping deformations (i.e., gap defects) that significantly influence fatigue crack initiation and propagation rates, as well as the stiffness and fatigue resistance of the overall structure. Therefore, investigating fatigue evaluation parameters for RSW with gap defects is crucial for predicting service life accurately. Currently, there is a need to refine and optimize fatigue evaluation parameters for such defects. This study introduces a two-dimensional equivalent decomposition model for RSW with gap defects, deriving an analytical solution (AS) for the stress intensity factor (SIF) at critical locations based on linear elasticity theory. The finite element solution (FES) is obtained through finite element analysis. The results demonstrate a high level of consistency between the AS and FES, enhancing the SIF solution approach. Additionally, the analysis of fatigue evaluation parameters (FEP), a precise fatigue life prediction model with a correlation coefficient of 0.9019 is developed. This model offers theoretical support for practical engineering applications.

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带间隙缺陷的电阻点焊疲劳评价参数研究

电阻点焊是汽车车身结构中常用的薄板连接方法，直接影响到结构的安全性。诸如板材成形回弹、装配偏差和制造误差等变化通常会导致焊接前板材之间的初始间隙（IGs）。这些间隙会加剧不均匀的塑性变形，导致翘曲变形（即间隙缺陷），从而显著影响疲劳裂纹的萌生和扩展速度，以及整个结构的刚度和抗疲劳性能。因此，研究具有间隙缺陷的焊接材料的疲劳评价参数对于准确预测其使用寿命至关重要。目前，需要对此类缺陷的疲劳评价参数进行细化和优化。本文引入了含间隙缺陷的点焊墙二维等效分解模型，基于线弹性理论推导了临界位置应力强度因子的解析解。通过有限元分析得到了有限元解（FES）。结果表明，AS和FES之间具有高度的一致性，从而增强了SIF解决方法。通过对疲劳评价参数（FEP）的分析，建立了相关系数为0.9019的精密疲劳寿命预测模型。该模型为实际工程应用提供了理论支持。

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

Theoretical and Applied Fracture Mechanics 工程技术-工程：机械

CiteScore

8.40

自引率

18.90%

发文量

435

审稿时长

37 days

期刊介绍： Theoretical and Applied Fracture Mechanics'' aims & scopes have been re-designed to cover both the theoretical, applied, and numerical aspects associated with those cracking related phenomena taking place, at a micro-, meso-, and macroscopic level, in materials/components/structures of any kind. The journal aims to cover the cracking/mechanical behaviour of materials/components/structures in those situations involving both time-independent and time-dependent system of external forces/moments (such as, for instance, quasi-static, impulsive, impact, blasting, creep, contact, and fatigue loading). Since, under the above circumstances, the mechanical behaviour of cracked materials/components/structures is also affected by the environmental conditions, the journal would consider also those theoretical/experimental research works investigating the effect of external variables such as, for instance, the effect of corrosive environments as well as of high/low-temperature.