Resistance spot welding of 6061-T6 aluminum: Failure loads and deformation

R. S. Florea; K. N. Solanki; D. J. Bammann; J. C. Baird; J. B. Jordon; M. P. Castanier

doi:10.1016/j.matdes.2011.05.017

Resistance spot welding of 6061-T6 aluminum: Failure loads and deformation

R. S. Florea, K. N. Solanki, D. J. Bammann, J. C. Baird, J. B. Jordon, M. P. Castanier

Research output: Contribution to journal › Article › peer-review

47 Scopus citations

Abstract

This study offers a novel research approach to compare weld quality for different welding conditions in order to achieve optimal end-product results. Using electron back scatter diffraction (EBSD) scanning, tensile testing, and laser beam profilometry (LBP) measurements along with optical microscopy (OM) images, failure loads and deformation of 6061-T6 aluminum alloy, resistance spot welded (RSW) joints were experimentally investigated. Three welding conditions, nugget and microstructure characteristics were quantified according to predefined process parameters. Quasi-static tensile tests were used to characterize the failure loads in specimens based upon these same process parameters. Profilometer results showed that the larger the applied welding current, the deeper the weld imprints. In addition, good correlation was obtained between the EBSD scans and the welding conditions. A strong dependency was found between the grain size and orientation and the welding parameters.

Original language	English (US)
Pages (from-to)	624-630
Number of pages	7
Journal	Materials and Design
Volume	34
DOIs	https://doi.org/10.1016/j.matdes.2011.05.017
State	Published - Feb 2012
Externally published	Yes

ASJC Scopus subject areas

General Materials Science
Mechanics of Materials
Mechanical Engineering

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title = "Resistance spot welding of 6061-T6 aluminum: Failure loads and deformation",

abstract = "This study offers a novel research approach to compare weld quality for different welding conditions in order to achieve optimal end-product results. Using electron back scatter diffraction (EBSD) scanning, tensile testing, and laser beam profilometry (LBP) measurements along with optical microscopy (OM) images, failure loads and deformation of 6061-T6 aluminum alloy, resistance spot welded (RSW) joints were experimentally investigated. Three welding conditions, nugget and microstructure characteristics were quantified according to predefined process parameters. Quasi-static tensile tests were used to characterize the failure loads in specimens based upon these same process parameters. Profilometer results showed that the larger the applied welding current, the deeper the weld imprints. In addition, good correlation was obtained between the EBSD scans and the welding conditions. A strong dependency was found between the grain size and orientation and the welding parameters.",

author = "Florea, {R. S.} and Solanki, {K. N.} and Bammann, {D. J.} and Baird, {J. C.} and Jordon, {J. B.} and Castanier, {M. P.}",

note = "Funding Information: The authors would like to thank the Center of Advanced Vehicular Systems at Mississippi State University and the US Army-TARDEC for supporting this work. This material is based upon work supported by the US Army TACOM Life Cycle Command under Contract No. W56HZV-08-C-0236 and was performed for the Simulation Based Reliability and Safety (SimBRS) research program. Any opinions, findings and conclusions or recommendations expressed in this material are those of the author(s) and do not necessarily reflect the views of the US Army TACOM Life Cycle Command. J.C. Baird offers thanks to the Mechanical Engineering Department at Mississippi State University for funding this research.",

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AU - Solanki, K. N.

AU - Bammann, D. J.

AU - Baird, J. C.

AU - Jordon, J. B.

AU - Castanier, M. P.

N1 - Funding Information: The authors would like to thank the Center of Advanced Vehicular Systems at Mississippi State University and the US Army-TARDEC for supporting this work. This material is based upon work supported by the US Army TACOM Life Cycle Command under Contract No. W56HZV-08-C-0236 and was performed for the Simulation Based Reliability and Safety (SimBRS) research program. Any opinions, findings and conclusions or recommendations expressed in this material are those of the author(s) and do not necessarily reflect the views of the US Army TACOM Life Cycle Command. J.C. Baird offers thanks to the Mechanical Engineering Department at Mississippi State University for funding this research.

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N2 - This study offers a novel research approach to compare weld quality for different welding conditions in order to achieve optimal end-product results. Using electron back scatter diffraction (EBSD) scanning, tensile testing, and laser beam profilometry (LBP) measurements along with optical microscopy (OM) images, failure loads and deformation of 6061-T6 aluminum alloy, resistance spot welded (RSW) joints were experimentally investigated. Three welding conditions, nugget and microstructure characteristics were quantified according to predefined process parameters. Quasi-static tensile tests were used to characterize the failure loads in specimens based upon these same process parameters. Profilometer results showed that the larger the applied welding current, the deeper the weld imprints. In addition, good correlation was obtained between the EBSD scans and the welding conditions. A strong dependency was found between the grain size and orientation and the welding parameters.

AB - This study offers a novel research approach to compare weld quality for different welding conditions in order to achieve optimal end-product results. Using electron back scatter diffraction (EBSD) scanning, tensile testing, and laser beam profilometry (LBP) measurements along with optical microscopy (OM) images, failure loads and deformation of 6061-T6 aluminum alloy, resistance spot welded (RSW) joints were experimentally investigated. Three welding conditions, nugget and microstructure characteristics were quantified according to predefined process parameters. Quasi-static tensile tests were used to characterize the failure loads in specimens based upon these same process parameters. Profilometer results showed that the larger the applied welding current, the deeper the weld imprints. In addition, good correlation was obtained between the EBSD scans and the welding conditions. A strong dependency was found between the grain size and orientation and the welding parameters.

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Resistance spot welding of 6061-T6 aluminum: Failure loads and deformation

Abstract

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