Failure Study of Two Dissimilar Steels Joined by Spot Welding Technique

Abstract:

Resistance spot welding (RSW) process is of paramount importance in automotive industry for the fabrication of metallic components. Several dissimilar alloys could easily be joined by resistance spot welding. However, the joining of the stainless steel and galvanized carbon steel is challenging task since weld fusion zone properties are affected significantly. Indeed, the reliability of the component lies in the sound quality of spot weld. The overload failure mode of the weld zone was determined by preparing lap-shear specimens and then carrying out tensile-shear test. Microstructures and hardness of the weld nuggets were also brought under considerations. It was found that weld nugget size and strength of that sheet material which has lower electrical resistance are the controlling factors of the failure mode. The aim of this study was to find out the causes of spot welds failure in terms of parameters favoring the pull-out failure mode, role of fusion zone size (FZS), nugget and base metal by controlling the process parameters.

• Periodical: Key Engineering Materials (Volume 778)
• Pages: 262-267
• DOI: https://doi.org/10.4028/www.scientific.net/KEM.778.262
• Online since: September 2018
• Authors: Ali Dad Chandio*, Nabeel Ahmed Khan, Rameez Jawaid, Syed Naqi Mohsin
• Keywords: Failure Mode, FZS, Interfacial Mode, Pull-Out Mode, Resistance Spot Welding

References

[1] S. Aslanlar, A. Ogur, U. Ozsarac, E. Ilhan, Z. Demir, Effect of welding current on mechanical properties of galvanized chromided steel sheets in electrical resistance spot welding, Mater. Des., 28 (2007) 2-7.

DOI: 10.1016/j.matdes.2005.06.022

[2] M. Pouranvari, P. Marashi, Resistance Spot Welding of Unequal Thickness Low Carbon Steel Sheets, in: Advanced Materials Research, Trans Tech. Publ., 83 (2010) 1205-1211.

DOI: 10.4028/www.scientific.net/amr.83-86.1205

[3] P. Marashi, M. Pouranvari, S. Amirabdollahian, A. Abedi, M. Goodarzi, Microstructure and failure behavior of dissimilar resistance spot welds between low carbon galvanized and austenitic stainless steels, Mater. Sci. Eng. A, 480 (2008) 175-180.

DOI: 10.1016/j.msea.2007.07.007

[4] M. Pouranvari, Analysis of fracture mode of galvanized low carbon steel resistance spot welds, Inter. J. Multidisci. Sci. Eng., 2 (2011) 36-40.

[5] M. Pouranvari, Effect of welding current on the mechanical response of resistance spot welds of unequal thickness steel sheets in tensile-shear loading condition, Inter. J. Multidisci. Sci. Eng., 2 (2011) 178-189.

[6] L. Boriwal, R. Sarviya, M. Mahapatra, Failure modes of spot welds in quasi–static tensile–shear loading of coated steel sheets, Mater. Tod.: Proceedings, 4 (2017) 3672-3677.

DOI: 10.1016/j.matpr.2017.02.261

[7] L. Kolařík, M. Sahul, M. Kolaříková, M. Sahul, M. Turňa, Resistance spot welding of low carbon steel to austenitic CrNi stainless steel, Adv. Mater. Res., 875 (2014) 1499-1502.

DOI: 10.4028/www.scientific.net/amr.875-877.1499

[8] P. Marashi, M. Pouranvari, S. Amirabdollahian, A. Abedi, M. Goodarzi, Microstructure and failure behavior of dissimilar resistance spot welds between low carbon galvanized and austenitic stainless steels, Mater. Sci. Eng. A, 480 (2008) 175-180.

DOI: 10.1016/j.msea.2007.07.007

[9] R.A. Shawon, Investigation into physical and mechanical properties and failure mode of resistance spot welded dissimilar metal joints, Dissertation - Department of Materials & Metallurgical Engineering, Bangaladesh University of Engineering & Technology, (2014).

[10] P.C. Lin, S.-H. Lin, J. Pan, Modeling of failure near spot welds in lap-shear specimens based on a plane stress rigid inclusion analysis, Eng. Frac. Mech., 73 (2006) 2229-2249.

DOI: 10.1016/j.engfracmech.2006.03.017