Effect of Forging Force on Fatigue Behavior of Spot Welded Joints of Aluminum Alloy 5182

[+] Author and Article Information
B. H. Chang, D. Du, B. Sui

Department of Mechanical Engineering, Tsinghua University, Beijing, 100084, P. R. China and Key Laboratory for Advanced Materials Processing Technology, Ministry of Education, P. R. China

Y. Zhou

Department of Mechanical Engineering, University of Waterloo, Waterloo, Ontario, N2L 3G1, Canada

Z. Wang, F. Heidarzadeh

Department of Materials Science and Engineering,  University of Toronto, Toronto, Ontario, M5S 1A4, Canada

J. Manuf. Sci. Eng 129(1), 95-100 (Jul 03, 2006) (6 pages) doi:10.1115/1.2383071 History: Received October 20, 2005; Revised July 03, 2006

Using experimental and finite element analysis methods, the effects of electrode forging force are investigated on fatigue behavior and residual stress of spot welded joints of aluminum alloy 5182. Results show that applying forging force significantly reduces the residual stresses in the heat affected zone and the fatigue cracks no longer initiate from there; instead, all cracks begin from the nugget edge. In addition, the mitigation of residual stress by forging force decreases the driving force for crack propagation and leads to longer fatigue life. It can be concluded that applying forging force appropriately has a positive effect on the fatigue strength of resistance spot welded joints.

Copyright © 2007 by American Society of Mechanical Engineers
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Figure 7

Materials properties used in finite element analysis: (a) material properties for thermal analysis and (b) material properties for thermal mechanical analysis

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Figure 8

Distribution of the first principal residual stress σ1 in the radial direction

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Figure 9

Distribution of the first principal residual plastic strain εp1 in the radial direction

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Figure 6

Mesh used in finite element analysis

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Figure 1

Shape and dimensions of the overlapped spot welded joints (unit: mm)

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Figure 2

Variations of electrode force and electric current during RSW process

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Figure 3

Fatigue test results for the two types of joints

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Figure 4

Two modes of fatigue crack initiation in spot welded joints

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Figure 5

The microhardness pattern of spot welds; the black lines show the boundary between the weld and surrounding area



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