Effect of Fatigue Test on Spot Welded Structural Joint

Abstract

Spot welding is mainly used method in joining sheet metals for body structure in automotive industry. The comprehension of the fatigue strength for the spot welds is very critical in automotive component design. Parameter for the resistance spot welding and fatigue machines is constant for each specimen used. The S-N curve is obtained from the fatigue testing for each specimen. This experiment parameters are varies the different thickness and different material combination in spot welding structure to investigate the fatigue life cycle and fatigue stress. For 1050A aluminium joint, fatigue life cycle and fatigue strength will decrease from number of cycle 500 at 16.58 MPa to number of cycle 61 at 6.62 MPa as the thickness increase. The fatigue life cycle and fatigue stress for galvanized iron will increase from number of cycle 46 at 9.25 MPa to number of cycle 1500 at 57.8 MPa when the thickness of joint increase. The finding from the combination of 1050A aluminum and galvanized iron on spot welded structure has shown no improvement in term of fatigue life cycle and fatigue strength because specimens experienced failure at number of cycle 19 with fatigue stress 2.36 MPa.

Investigating Spot Weld Fatigue Failure with Experimental and Finite Element Analysis Methods

“…The fatigue crack initiation in LCF primarily occurs in the base material. The crack propagation occurs in the HAZ or the region close to the FZ [70]. In this work, HCF was predominant, because the applied load was below the yield strength of the spot welded joints.…”

“…Because, to the author's knowledge, there are no results about Al-Cu spot weld fatigue. Figure 22 shows the 1050 aluminum RSW joining fatigue life simulation work and from the previous study [70]. At the same conditions as the ABAQUS simulation, the 1050 aluminum joining at the maximum applied load (1.646, 1.373, 1.177, 0.746, 0.673, 0.530, and 0.314 kN).…”

The Box-Behnken Response Surface Methodology Approach to Optimize Tensile Strength Load in Resistance Spot Welding Using SPCC-SD Steel

“…The exceptional qualities of SPCC-SD steel make it extremely adaptable, making it the preferred option in various industrial sectors. Its applications encompass a wide range of fields, such as automotive manufacturing, electronics, household appliances, and precision engineering, due to its dependable performance and versatility in different environments [26]. The chemical composition and materials utilized in this research are presented in Table 1.…”

Tensile shear load in resistance spot welding of dissimilar metals: An optimization study using response surface methodology

“…The process involves the resistance of electricity heating the metal surfaces to melt and fuse at the welding site [10], [11]. The subjection of the metal welding contacts to the heat produced by electric resistance usually leads to the melting of the metals [12]. The RSW process is normally conducted within a specific cycle time using several parameters such as the welding current and time as well as the electrode force [13].…”