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Failure Mechanisms and Shunt Effect Phenomenon in Single- and Double-Nugget Resistance Spot Welded HSLA Steel

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Abstract:

This work presents an experimental investigation for the failure mechanisms and shunt effect phenomenon in resistance spot welded high-strength low-alloy (HSLA) steel sheets with single-and double-nugget configurations. Welded joints were produced under controlled conditions following to ISO/DIS 14273:2016 standard, and their performance was assessed through tensile-shear testing, microhardness measurements, and microstructural analysis. The results revealed a clear influence of nugget configuration on both mechanical strength and fracture behavior. Single-nugget welds primarily exhibited interfacial and partial pull-out failures, whereas double-nugget welds demonstrated combined pull-out and sheet-tearing modes, indicating improved energy absorption and joint integrity. Microstructural observations showed refined martensitic zones in the fusion region, with hardness values significantly higher than those of the base metal. The shunt effect phenomenon observed in double-nugget welds led to noticeable variations in nugget diameter and hardness symmetry, influencing current distribution and local heat input.

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Periodical:

Materials Science Forum (Volume 1199)

Pages:

73-88

DOI:

https://doi.org/10.4028/p-9sOrLv

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Online since:

August 2026

Authors:

Hayder H. Khaleel*, Ibtihal Mahmood, Fuad Khoshnaw

Keywords:

Electrode Force, Failure Mode, Resistance Spot Welding, Shunt Effect Phenomenon, Tensile-Shear Test

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© 2026 Trans Tech Publications Ltd. All Rights Reserved

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