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An approach in prediction of failure in resistance spot welded aluminum 6061-T6 under quasi-static tensile test
KTH, School of Engineering Sciences (SCI), Aeronautical and Vehicle Engineering, Lightweight Structures.
Iran Univ Sci & Technol, Tehran, Iran.
KTH, School of Engineering Sciences (SCI), Aeronautical and Vehicle Engineering, Lightweight Structures.ORCID iD: 0000-0003-4180-4710
Linkoping Tech Univ, Linkoping, Sweden .
2012 (English)In: Proceedings of the Institution of mechanical engineers. Part B, journal of engineering manufacture, ISSN 0954-4054, E-ISSN 2041-2975, Vol. 226, no B6, 1026-1032 p.Article in journal (Refereed) Published
Abstract [en]

The aim of this article is to predict the failure load in resistance spot welded aluminum 6061-T6 sheets with 2mm thickness under quasi-static tensile test. Various welding parameters, e. g. welding current, welding time and electrode force are selected to produce welded joints with different quality. The results show that for all the samples in this study only interfacial failure mode was observed in tensile-shear test and no pull-out mode was observed. According to the failure mode, an empirical equation was used for the prediction of failure load based on nugget size and hardness of failure line. Microstructure study has been carried out to investigate microstructural changes in the welded joints. For determination of the minimum hardness, microhardness tests have been carried out to find hardness profiles. The minimum hardness value was observed for a thin layer around the nugget with large and coarse grains. The results show that by using the presented empirical equation, the failure can be predicted with a good agreement only by measuring nugget size.

Place, publisher, year, edition, pages
2012. Vol. 226, no B6, 1026-1032 p.
Keyword [en]
Resistance spot welding, aluminum 6061-T6, failure load, nugget size
National Category
Vehicle Engineering
Identifiers
URN: urn:nbn:se:kth:diva-99091DOI: 10.1177/0954405411435198ISI: 000305483000006Scopus ID: 2-s2.0-84871967532OAI: oai:DiVA.org:kth-99091DiVA: diva2:541470
Note

QC 20120718

Available from: 2012-07-18 Created: 2012-07-13 Last updated: 2017-12-07Bibliographically approved
In thesis
1. Mechanical Properties of Resistance Spot Welds in Lightweight Applications
Open this publication in new window or tab >>Mechanical Properties of Resistance Spot Welds in Lightweight Applications
2013 (English)Licentiate thesis, comprehensive summary (Other academic)
Abstract [en]

This licentiate thesis is concerned with residual stresses in aluminum alloy 6061-T6 resistance spot welded joint. Several topics related to mechanical strength of welded structures are treated such as; nugget size and microhardness and microstructures of weld zone and their influence on mechanical strength of welded structure, failure load measurement using tensile-shear test, resistance spot welding simulation, residual stress measurement by X-ray diffraction method and analysis effect of welding parameters on the mechanical strength and the residual stresses.

To investigate the effect of resistance spot weld parameters on mechanical strength of welded structures, various welding parameters e.g. welding current, welding time and electrode force are selected to produce welded joints with different quality. According to the failure mode, the empirical equation was used to prediction of failure load base on nugget size and hardness of failure line. Microstructure study has been carried out to investigate microstructural changes in the welded joints. Microhardness tests are done to find hardness profiles due to microstructural changes and determine the minimum hardness.

In addition, an electro-thermal-structural coupled finite element model and X-ray diffraction residual stress measurement have been utilized to analyze residual stresses distribution in weld zone. The electrical and thermal contact conductance, as mandatory factors are applied in contact area between electrode-workpiece and workpiece-workpiece to resolve the complexity of the finite element model. The physical and mechanical properties of the material are defined as thermal-dependent in order to improve the accuracy of the model. Furthermore, the electrodes are removed after holding cycle using the birth and death elements method. Moreover, the effect of welding parameters on maximum residual stress is investigated and a regression model is proposed to predict maximum tensile residual stresses in terms of welding parameters.

The results obtained from the finite element analysis have been used to build up two back-propagation artificial neural network models for the residual stresses and the nugget size prediction. The results revealed that the neural network models created in this study can accurately predict the nugget size and the residual stresses produced in resistance spot weld. Using a combination of these two developed models, the nugget size and the residual stresses can be predicted in terms of spot weld parameters with high speed and accuracy.

Place, publisher, year, edition, pages
Stockholm: KTH Royal Institute of Technology, 2013. v, 19 p.
Series
Trita-AVE, ISSN 1651-7660 ; 2013:45
Keyword
Spot Weld, Aluminum alloy, Mechanical Properties, Finite Element
National Category
Vehicle Engineering
Research subject
SRA - Production
Identifiers
urn:nbn:se:kth:diva-131306 (URN)978-91-7501-838-6 (ISBN)
Presentation
2013-09-30, M37, Brinellvagen 64, KTH, Stockholm, 13:15 (English)
Opponent
Supervisors
Projects
No
Note

QC 20131014

Available from: 2013-10-14 Created: 2013-10-12 Last updated: 2013-10-14Bibliographically approved

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Barsoum, Zuhier

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