Microstructural and interface geometrical influence on the mechanical fatigue property of aluminum/high-strength steel lap joints using resistance element welding for lightweight vehicles: experimental and computational investigation

Baek, Seungyeop; Go, Gun Yung; Park, Jong‐Wook; Song, Jee-Hun; Lee, Seung-Joon; Lee, Sang‐Min; Chen, Chuantong; Kim, Minsu; Kim, Dong-Jin

doi:10.1016/j.jmrt.2022.01.041

Cited by 27 publications

(12 citation statements)

References 43 publications

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“…However, numerical studies using FEA technologies could be helped reducing costs and providing an effective compliment to experimental work. Many researchers [55][56][57][58][59][60][61][62] have carried out the numerical analyses for REW with considering different electrical, thermal and mechanical phenomena such as formation of temperature field and welding nugget growth. Generally, the REW process involved multiple inter-metallic contacts, leading to more complex dynamic electric current flow, heat generation, transfer and nugget growth.…”

Section: Numerical Analysesmentioning

confidence: 99%

“…The simulated results showed that a numerically optimized welding rivet geometry might be guaranteed sufficient joint strength. Baek et al 56) studied a 3D Finite Element Method(FEM) modeling for mechanical simulation using the commercial finite element code ANSYS. It could be found through numerical simulation that the stress and strain distributions showed a significant difference to the same fatigue load according to the geometrical effect of the welding interface.…”

Section: Numerical Analysesmentioning

confidence: 99%

“…It could be concluded from the study that the relationship between hollow sphere weld and re-solidified Mg alloy was similar to the flesh and core of a drupe. A method of assembling lap joints through a simple approach to AA5052 and SPFC980 steel using REW was studied 56) . It could be revealed that fatigue properties had the highest fatigue strength at 10.5kA.…”

Section: Microstructure Analysismentioning

confidence: 99%

See 2 more Smart Citations

An Overview of Resistance Element Welding with Focus on Mechanical and Microstructure Joint and Optimization in Automotive Metal Joints

Shim

Park²,

Kim

2023

J Weld Join

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As lightweight automotive structures improve fuel efficiency and reduce carbon dioxide emission, they have garnered extensive attention. Vehicle mass reduction, which is a key problem for next generation eco-friendly vehicles, can significantly increase mileage. Hence, industries have committed to replace conventional materials with lightweight materials, such as advanced high strength steel. Additionally, automotive industries are hindered by challenges in the field of joining technology. A novel welding technology called resistance element welding (REW), which is an appropriate thermal-based joining method, was developed recently for joining hybrid materials with other structural steel grades. In this study, the state of the art joining and the process characteristics for dissimilar metal joints have been presented because related studies show limited investigation in this area. Following by the state of them, the principal and welding quality of REW, experimentally and numerically, are reported to give comprehensive information on the current practices and research interest related to technologies. Finally, extensive work was concentrated on portional joining optimization techniques to improve different materials.

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Section: Numerical Analysesmentioning

confidence: 99%

Section: Numerical Analysesmentioning

confidence: 99%

Section: Microstructure Analysismentioning

confidence: 99%

See 1 more Smart Citation

An Overview of Resistance Element Welding with Focus on Mechanical and Microstructure Joint and Optimization in Automotive Metal Joints

Shim

Park²,

Kim

2023

J Weld Join

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“…Gunter and Meschut [19] took conical rivet as the element and carried out self-penetrating REW between AA and steel without prefabricated holes. Recently, REW has been used to weld different combinations of AA and steel, such as A6061/22MnMoB [20], A6061/HS1300T [21], A6061/DP600 [22], A6061/Q235 [23], A5052/SPFC980 [24]. The results show that REW of AA and steel using the steel as a lower plate and steel rivet as an element can successfully transfer the bearing interface of the joint to the steel/steel interface, thus improving the performance of the joint.…”

Section: Introductionmentioning

confidence: 99%

Resistance element welding of aluminium alloy and steel using an element of aluminium

Qiu

Zhao

et al. 2023

Science and Technology of Welding and Joining

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Aluminium alloy AA6061 and mild steel Q235 were welded by resistance element using an aluminium rivet as the element. The microstructure and properties of the joints were characterised. The temperature distribution on the cross-section of the joints was calculated by using ABAQUS numerical simulation software. The observation results on the cross-section of the joints show a nugget formed at the interface between the rivet tip and steel of lower plate. The maximum tensile shear load of the joints reached 5.82 kN at the welding current of 26 kA. This study reveals that the bearing interface of the resistance element welded joint between aluminium alloy and mild steel is like-to-like interface of aluminium alloy which strengthens the joint.

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“…Wang et al 23 experimentally optimized the performance of the effect of weld design on the fatigue strength of resistance spot‐welded T‐joints and laser beam welding for automotive applications. Baek et al 24 proposed an experimental and computational approach for analyzing the influence of microstructure and interfacial geometry on the mechanical fatigue performance of aluminum/high‐strength steel lap joints for lightweight vehicles. Based on the Bayesian statistics approach, Zhigang et al 25 studied the failure mode effects on the fatigue properties of vehicle exhaust products.…”

Section: Introductionmentioning

confidence: 99%

Fatigue performance investigation on the automotive welded structure under damped loads using the Taguchi method

et al. 2022

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In the present paper, a three-dimensional numerical model has been built using ANSYS code to analyze the static and fatigue behavior of a welded design based on four rectangular profiles under damped loads for automotive application. The fatigue of the proposed design is generally influenced by a number of factors. The aim of this study is to investigate the effect of the load level, the stress ratio, the mean stress theory, the geometry size, the weld bead height, the temperature of the weld bead on the durability (P 1 ), and the

show abstract

Microstructural and interface geometrical influence on the mechanical fatigue property of aluminum/high-strength steel lap joints using resistance element welding for lightweight vehicles: experimental and computational investigation

Cited by 27 publications

References 43 publications

An Overview of Resistance Element Welding with Focus on Mechanical and Microstructure Joint and Optimization in Automotive Metal Joints

An Overview of Resistance Element Welding with Focus on Mechanical and Microstructure Joint and Optimization in Automotive Metal Joints

Resistance element welding of aluminium alloy and steel using an element of aluminium

Fatigue performance investigation on the automotive welded structure under damped loads using the Taguchi method

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