Investigation on Fatigue Strength of Aluminum Alloy 6061-T6 Resistance Spot Welded Going under Tensile-Shear test
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nvestigation on Fatigue Strength of Aluminum Alloy 606-T6 Resistance Spot Welded Going under Tensile-Shear test D. Afshari Faculty of Engineering, University of Zanjan, Zanjan, Iran F. Sardarzadeh Faculty of Engineering, University of Zanjan, Zanjan, Iran N. Noorafshan Faculty of Engineering, University of Zanjan, Zanjan, Iran Abstract Resistance spot welding(rsw) is one of the most popular welding methods in joining sheet metals of cars, and etc. In RSW process, a high electric current is passed throw two sheets via electrodes, which results in the generation of a melting zone between the sheets, called nugget. The main purpose of this study is experimental investigation on static and fatigue strength of aluminum alloy 606-T6 with 2 mm thickness. To achieve this goal, many samples were prepared and welded by different RSW s parameters. The mechanical strength of welded samples was examined under tensile-shear test. The results show that, by increasing the nugget size, the static strength is improved. In addition, however at first, the fatigue strength is increased by improving the nugget size; it s decreased significantly after a certain nugget diameter. The micro-structural study indicates the formation of cracks in the HAZ after the certain nugget diameter. However, these liquation cracks have no effect on the static strength of spot welded samples; they cause dramatically changes in the fatigue strength of samples. Keywords: Resistance Spot Weld, Fatigue Strength, Static Strength, Nugget size, Tensile-Shear Test ;8 -C 6, C / 8 F, :8 :8 > (@ ; 7.[] 5 7, 6 :? (@ P> C 8 JU S e? A ).> )- S 8 C b ^ PQ W^ fh: 7 8 AB= 8 8,.@ 6 :? (@ 6 YJ= H : J> 6 GHI J J? :8 6 :? (@ AB F,, 8 6 YJ= 8 3 (@ J- :O PQ (@ 8 6> b 6 8 GHI 6>, ; AB / ABZ 4 2Ja 6 8 (@ J- :O J GHI Ig :O 8 4 T >., 5 ^ fh: 7 8 AB 3-.O AB 6.5 ; :?? (@ <U 2, H8O <3.,\8 U,.58 GHI 6QH AB H8O ] Z 6\8 Q J 8 4 > J.58 6 :?? (@ ]^BC ; J.4 W^ 2 65@ ; 84. > _ 6> 4, >J> >:O 64,C64,? H98 > ` a 4 U ; Z ; PQ 8 3 b AB Z AJU 2 8 2QJ> (@ J (@ J- Y. - (@ J- b AB 8 3 > F, * dafshari@znu.ac.ir : 95/02/9 :! 95/07/03 :( )!
2 <=k, k ]9: 5 5 :J> 7k, k Vk, k - ]k^ 6\k GkHI 6>D 0C kj k 6>D 6 :? (@ AB ; 9: PQk 8 C ; T >., - k. PQk 8 64, C W^ >D ; 4 7, YJ Pk S 200 A, [9] PJ> Z At 298., k <k Dk 0kC <=k, 6 k8 Jk 6> ;knj>.k ko k9: = 2J ( 4 7,!k, ( 4 7k, k8 [0] PJ> 2C u Y_ 202 A, 606 <k Dk 6 :? (@ AB <=, X:,. J 8 P = (k@ AkB <=k, k4 k - ]k^ ]k9: k 0kC k, <=k, 7 > > 2 6 :?.k58 k )- S (@ 4, 7 AB 24 7 ;, 8, 5 9, Q 9: ; ko 9: 606-T6 < 6 :? (@ AB (k@ kj- k:o ;8k k:8 k, k5 (vk ;knj>. - kk ;k8. k- ko k, 8 k 0C, <=, 6 k:? (k@ F, 5 65@ 6> J 4 6 UJ3 k, 8 k8 GHI 8 3 6> 244 7, 8 5? k k.8 [ 6 k8 ;knj>.k, k5 kc k> k ;., - O, 8 J > W:? X:, > J 0C ('. 5C 8-2 b 4 6 k:? (k@ AB <=,, : ;.k, 5 7, H 2 Ig T6 < D Cr 0/., 5 w 7, D J5 h 606-T F G>'. -,4 Cu 0/2 Fe 0/5 Mn 0/ Mg /0 Si Al 97 6\8 A@ J5 BU 4 ^ Hk,8 kj k> (k@ Yk= k8 > J 65@ 6 8 ;k5 4 7k, k8 65@ rl, 5 4, Fkk,200 kava kk 2kk kk8 PMP DGS Akk NIMAK Yk5 k5 6> J 98., 5 <3 6> 0/6., 5 PJ ' (?I(/) 5 5C?I(/-H ( ( f) P5 <U T h: (@ J-., 5 ^ 6:? (@ ;Z 6 :? (@ AB F,, YJ= i e. 8 6> (@ AB 0C <=, , C / J>.58 AB 7 ;9 j 9 6 :? (@ F, 5 65@ 6> 4, 4 AB 0C <=, ).58 J 6>8 4 6> 4, Z a, 6 g 6> e.,5 - O K 8 JU H8O J K e. 8? (@ ]\B 0C <=, S YU 2 6 :? (@ AB 0C <=, 9: ; 4.58., - O 68 Jk 6> P S, A, [2] PJ> 0\ b 6 k:? (k@ lk, 6> Y5 m 6 8 0C 6k> P5 4 7, 8 [3] PJ> n. C 6\ k k= 2kJ Ak /k 4 7, 8 P 8 8 6C, k \k8 <=k, k8 6\ 6> b 6 :? (@ 0C ek, 6 k8 ( ;k 4 2k k 2 O 9: 2008 Ak, [4]QJk, (k. 7, JU -<=, = k9: 0C <=, :? (@ 6> S kju k= 2kJ ( 4 7k, 8 [5] n5 n. O AkB Z I, W4, 8 6 :? (@ AB 0C /k [6] 2-k ;k ;knj>.k ko k8 P 7k, k8 B 6> 6)-8 0C JU 0 9: 9 k5.k ko k8 Pk 9a r ] m 4 /k 6 k:? (k@ 0kC <=k, 200 A, [7] 8 m 2 k H,8 6\ b k8 Jk 6k> Pk ks ; k- kk 8 Q [8] =^ k5 6 :? (@ 0C JU [ ( - ( 4 7,. J 64, k 8 > 64, C W^ ]QH ;8 4 kj> Dk rk@ fi 6 8,, BI / 2U k, 64k, C _.k58 k k,, Yk^ /k \8 <=, RkC Yk k8 k> - > W^. - kqh /, > 4, 8 HJ@4 e ]7 6>D k O 7k, k> 6k> 4, 2, 4 8 B= 7k, k k ; H^ 4 >D ; Q 2 e>. - Qk 64k, kc Wk^.k58 _ > 6> 4, 4 k> GkHI 6k>C < 6>D 4 7, YJ kh98 <k 6k>D 6 :?5@ T -.58 PQ AZ k ;k k Vk58 k \k 4 Y 2 s Z RC Wk^ k 6k> b AkB ( ; k8 2kNJ>.58 GHI... D? 6:? (@ AB 0C, 8 kj- k:o k8 AkB k <=k, :8, 8 <Q 8 (k@ kj- GkHI 6> :O @ 6> J (@ Mesh-intensive structural stress approach 2 Tensile-Shear test 50
3 2 H 4, x 6.k k5 } (.70ml 60ml HN 0ml HF) Jk5 AH= 4 Pk 2 k /kc k5 k> kj 64, HZ.58 6l, 4 7, 8 C, Q 9: NF-3 J- :O 8 AB 0C, <=, :8, 8.@.@ 65@ GHI 6> 8 > J 65@ 8 4 (@ <4\ kk ;k8.k58 k (@ J ]7 6> :O 8 8, kh 2 Ig 8 b 6 8 (@ J- :O 8 J,, 8 (@ J- :O J fi 9: ;.5 ;9 6 k kh2 Ikg 8 6> b 6 8 [] AWS, ^ k:o k8 fki ;knj>., 5 - K H 5/7 65@ f) P5 4 f@ 8 Q (@ J-.[2], 5 ;9 H 8/5 GkHI 6> (@ J- :O AO Y8O = 8 k - kk (k@ J- 6> :O 8 8,.@ 6 :? (@ <k3 4 k98 k5 6k5@ kj k>. - O, k- 4k (@ J- :O 5 8 AB Y= 4 (@ k.@ 6 k:? (k@ 6k> ]kuva ; 6 8, 5 7 2k.k, k5 X=B K (@ J- :O 8 8, 6 k8 6 k:? (k@ GHI 6> @ J 6, AkJU (@ 6> 2 A@. 5 fi 9: ;, 8 kw (k@ kj :O 4 8 J> > J 4 6, > , C. 5/'(,O/ 5/ C'/-2,4 (@ J- :O (mm) 5/72 5/95 6/42 7/06 7/49 7/98 8/4 (@ 24 (ms) ]5 (ka) , GHI 6> 2= 8 8 K ; : ; k5 6 k- 4k GkHI 6k> J (@ J @ 6k yk, /k 4 7k, k8 (@ J- :O 6-4. kj > K ;8., 5 <3 6 l e, / 8 YB 4 rk k5 k 8 AB Y= 4 6 :? (@ < kj- 2 Yk5.k, k5 6 k- 4 (@ J- :O 64,.> PJ 5 65@ J / (@ L4 4?,-./ M? 0 >?-2H 2k4 ;k5 4 7, 8 > J (@ J- :O 25 zi 8 k8 k5 8-k, 6)-8 = J > (3 kj k> k, <=k, k - O mm/min Y5) 8S U, 6 k- 4k k9: ;k ;NJ>.k - ko 6 k- 4 ]k^ k5 8-k 6)k-8 = Q J > 0C <=, k>8 4 K ; 6 8., - (R=0) 7k^ 6)k-8 k8s k 0 HzJk8 k8., 5 7, 5 2 A@ 5 w 6> J J 6 8, ~ 8 <4\ 20 ; 4000 h 8 8S (@ P , > 6 8 9: ;., 5 - K S H - J 9 2 J5 A@ 5 w (@ 6> AB 0C, <=,, J 63 J3., - O, 8 (@ (k@ kj- :O 5 65@ 6> J 25 zi 4 r -k 2k4 6 8 J 4 6, > 4 J 3 > J 4 6, > ko 6 k- 4k > J, <=, ;9.@ 5 8 k:o (k@ AkB, <=, 2 :8 4 Y5. - YkJ= 8 ; 8, ~ 8 <4\.> PJ (@ J- k5 YkJ= k8 ; k8 ; Y5 5 w 5?8 5C '( ==> 8-3H 6k> kj 0kC k 4 k.8 [ 6 k8 k9: ;k yk, /k 4 7k, k8 kj > W:? X:, V5 65@ 6k5@ 4 rk kk ;k8.k, - O 9: 6 k 4 7k, k8 5 3 AB Z 5 8 J > AB 6k> J. 5 y, 4 9: 6 8 > J < - /k 4 7, 8 rl, 5 P HZ ;T a 5
4 k> 6 k8 k5 2k4 kj 3 AB 5 4 P (@ AB.58 > J 4 6,... D? 6:? (@ AB, 8 0C 5 5C *+ 'O /?-6H 8 8 PQ 8, zi 6 J5 Y5 :J> P> > J 4 6, > 6 8 0C JU 5 65@ J 0C JU = ]7 >J ; e.., > J, 8 H 8/4 7/98 :O 8 > J AB H 7/49 8 H 5/72 4 (@ J- :O PQ (@ 6> J 0C <=,, <=, 0C JU P> > J 4 6, ; 6 8., PQ = AB 0C JU Z > J 4 6, ; JU H = ;.,?, 20 5 = 8 (@ AB 0C ? 0C JU P> 0JT > J 0C JU Z.5 > Q O 0 5 = =., 0 4 = 8 (@ AB 0C JU 3 8 PQ Q H 8/4 7/98 :O 8 6> J 6 8 6k> JU k.k, k5 6 :? (@ AB 0C JU P> 8 kj 4 ]k7 Y :8 > J 6, ; S 0C k8 H 7/49 4 (@ J :O PQ 8.58 ; 6> <=k, (k@ AkB k, <=, vc 8 H 7/98 0C JU Z., P> ]5 8 AB 0C Vk58 k k 000 k8 k= 7/49 k k P>k 2258 k8? ; 7/98 8 :O 8 J :O 8 J 6 8 6)-8 J 5 65@ J 0C JU P> ;., >k Qk 6 k kh 8/4 kh 8/4 k8 k H.5 > > k:o k8 kj ; K 7/98 4 (@ J :O PQ 8.5 kju 2k?., 0C JU P> kj 6 k8 k k> k 2 GHI 6> 6)-8 = 0C J 6 H 8/4 :O 8 J 0C JU 5 AJU 6> H 7/98 :O 8 J 0C JU 4,-././ 6"/ 40 ;? '2P 2(/ /?-4H <=k, 2 J? :8 V, zi Y5 ; :J> k@ > J 4 6, > (@ J :O (@ AB, kj Fk, k5 YJ= 8 ; 8 (@ J :O PQ 8. 2k4 ;k.k, k k PQ (@ AB ;5 4 P kj 6 k8 ;k 32 (k@ AB F, 5 YJ= 8 ; J 4750 k5 YkJ= k8 ; k8 ( k kh 5/7) (@ J- :O k5 ks ( kjh 8/4) (k@ kj k:o k8 6 k8 ;k Yk= 4 6 k:? (k@ AkB 5 24 ; e.., k8 ; k8 PQk k@ k8.k58 k > J J 6 8 (@ k-q8 (k@ kj k:o 8 6> J 6 8 AB F, 5 YJ=.(5 Y5) - > > J 5 ;. 2NJ> kj 6 :? (@ AB, <=, r ko 7k, 0C <=, 6-4.@ O8 6> <=k, 2k4 k kj 42 kj3 k9: ;k. - k, 8 6 k8 k5 6k5@ kj 28 4.k, - O 0C ;k k>8 k= 0C <=,.8? = 0C , Y5., > J 4 6, > 0C <=, 2 k> kj 4 6 k, k> 6 8 0C 24 4 Y^Z J 6 J5 k= 6k> kj kh 6 k8 k k, ~ 8 <4\., PJ ;8 ]B8 > J AB Y= 4 5. Q 0C 6)-8. - > 6 =7^,-./ M / 5 5C <-5H 52
5 2 H 4, x 6 ((@ J :O PQ ) AB Z PQ 8,., PQ Q (@ J a < - 6> [ k5 8-k 2k4 = 5 65@ 6> J, 8 <=k, k8 6 Sk HAZ kz 6k> > 2 (k@ AB 3 ; 8. 6 :? (@ AB, kz ;.[4], 5 > Q 64 6>\ 6 :? <=, = > J. YkU k k> k 2k, 5 6 :? (@ AB 0C.k58 k 6 k:? (k@ AkB 0C <=, J. 8 kj k8 7 J > [ ; PQ > 2 M., 5 Q (@ AB 0C <=, 8 P> kk, kk> 6 kk8 0kkC kkju 2kk kk? 7 Jkk5 Ykk5 kju k k, k~ k8 <4\ J 3 8 = > J 0C JU ;0 J ; 5 2 0C (@ AB 0C 7 J5 Y5.58 > J4 6, > Z. 6 k k H 7/49 8 H J5 Y5 5 PJ 6 :? 5/72 4 (@ J- :O PQ 8 k5 (k@ 6k> kj 0kC <=k, k, <=, 8 H 7/49 4 (@ J :O PQ 8 V, PQ <=k, (k@ AkB k, <=, vc 8 H 7/98 k8 kj 6 8 > ;, P> AB 0C.58 > Y8O Q H 8/4 X:k, k5 6k5@ 6k> J 0C.8 [ 6 8 k~ k8 <4\.k - ko k, 8 AB Z > J W:? 6k5@ 6k> kj kj 6 8 > J X:,, 8, k.k, k >k AkB :O ka =:k, [ M> 5 6k> J 6 8 T > > 2 (@ W:? X:,, k> kj 6 k8 AB Z > 5 >k (HAZ) k S = Z > [ (@ J a 7 6 6k> kj (k@ Wk:? X:k, kb 8 Y5.5 8 Yk5 k (k@ kj- ka 6. WO.> PJ k kc- 6k. 8 < (G) 53 (f) 6 :U7/ 0 ;? R/'S/? 6'; 5C T'. -8H 7 :V 5 ( W-4 6 k:? (@ AB 0C, <=, 9: ; k, 8 k k H 2Ig T6 < D? k <=k, (@ J- :O 2 :8 ;NJ>. - O ;k 4 k k,8 Mk.k, k5 k9: 6 k:? (@ AB <=k, k8 J? S (@ J :O > 2 9: PQk k8 k3 2 PQk 6 :?k5@ AkB k,. - JB, <=, <=k, PQk k8 k3 (k@ k:o J PQ T > (k@ AkB 0C <=, 6 8 V - (@ AB, k k> k 2k 9: ; M. b^ Q- ; 6 :? k:o PQ H 2 Ig T6 < D b 6 8 0kC <=, P> 8 3 H 7/5 4 P8 8 (@ J.2000( <". 5 5C *+ 'O-7H ;kz AB Z PQ 8, K 8 AkJZ (k@ kj- k:o PQk 3 6 :? (@ ; - ]^ ]9:., PQ > [ ; 3 kz 8 5-6D 2Q 2 Q [4 ]k9: ;k.k58 k. k ; 3 3] ; J. AB 6 kz 6 :? (@ ;Z. ; 2 k hk@.5 Y, f~ Y :8 kj- 2 k8 k8 k. ( k- k. 2? 4 > [ ; zik Qk 8 Liquation crack Y5 :J>.58 b 6, (@
6 [] ANSI/AWS/SAE/997 Weld button criteria, recommendedpractice for test methods for evaluating the resistancespot welding behavior of automotive sheet steelmetal, American National Standard, 997. [2] Afshari D., SedighiM., BarsoumZ., and PengR. L., An approach in prediction of failure in resistance spot welded aluminum 606-T6 under quasi-static tensile test, Journal of Engineering Manufacture,vol. 226, no. 6, pp , 202. [3] Sankra J., and ZhangH., Cracking in spot welding aluminum alloy AA5754, Welding Journal, vol. 79, no. 7, pp , [4] Saha D. C., Chang I., and Park Y. D., Heat-affected zone liquation crack on resistance spot welded TWIP steels, Materials Characterization, Vol. 93, pp. 40-5, kU k> kj J X:, T (@ AB k8 k k> 2k AkB kz W:? X:,, 8 V58 [ < k- 6k. k kh 7/5 4 Pk8 k8 (@ J- :O PQ ;k.k, k k@8 S =?: (@ J- a.k58 k k@8 AB Z - PQ Y8. 65@ 6> J, <=, 8 6 S. ; T > 0kC <=k, k= k 8 3. V 5 6 k:? (k@ 6k> A k ; 8k8.k, 5 (@ AB.58 e. 8 AB. ; 4 9J.@ 4k, k k8 k@ 8 > 2 9: ; 4,8 M k O k 6k>8 j 9 AJ9 :8 5 65@ 6> k k> (k@ AkB k7 4 2Ja.@, <4\ - (@ 6> - O `O, 8 (@ AB 0C 0kC k, <=, 8 8 8,.@.8 6 :?. - ;9 AB 6 8 5/X*Y-5 kc O h C 7i? 2- k.@ wk, :Hk, 9k^ 0k C,. 4 6k>Q8 k> ;k5 k8 k,, 4@ <4\ ] 2 e> kb. 6O 4 ;NJ>.J 4 8 9: ; 4.5 > 24 <3 > J> 6 8 5C W/'-6 [] Sun X., Stephens E. V., and Khaleel M. A., Effect of fusion zone size and failure mode on peak load and energy absorption of advanced high strength steel spot welds under lap shear loading conditions, Engineering Failure Analysis,Vol. 5, No. 4, pp , [2] Longa X., Khanna S. J., andallardbl. F., Effect of fatigue loading and residual stress on microscopic deformation mechanisms in a spot welded joint, Materials Science and Engineering: A, Vol , No. 25, pp , [3] Kang H. T., DongP., and HongJ. K., Fatigue analysis of spot welds using a mesh-intensive structural approach, Internationa Journal of Fatigue, Vol. 29, pp , [4] ErtasA. H., and SonmezF. O., A parametric study on fatigue strenghth of spot weld joints, Fatigue & Fracture of Engineering Materials & Structures,Vol. 3, No. 9, pp , [5] Wang R. J., and ShangD., Low cycle fatigue life prediction of spot welds based on hardness distribution and finite element analysis, Internationa Journal of Fatigue, Vol. 3, pp , [6] WangR. J., and ShangD., Fatigue life prediction based on natural frequency changes for spot welds under random loading, Internationa Journal of Fatigue, Vol. 3, pp , [7]Shariati M., and MaghrebiM. J., Experimental study of crack growth behavior and fatigue life, Journal of Applied Science,Vol. 9, No. 3, pp [8] Mirsalehi S. E., and KokabiA. H., Fatigue life estimation of spot welds using a crack propagation-based method with consideration of residual stresses effect, Materials Science and Engineering: A,Vol. 527, No. 23, pp , 200. [9] Hassanifard S., ZehsazM. and EsmaeiliF., Spot weld arrangement effects on the fatigue behavior of multi-spot welded joints, Journal of Mechanical Science and Technology, Vol. 25, No. 3, pp , 20. [0] Faseeulla KhanM. D., DwivediD. K., and SharmaS., Development of response surface model for tensile shear strength of weld-bonds of aluminium alloy 606 T65, Materials and Design, Vol. 34, pp , D? 6:? (@ AB 0C, 8 54
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