Welding parameters influence on fatigue life and microstructure in resistance spot welding of 6061-T6 aluminum alloy

R. S. Florea, D. J. Bammann, A. Yeldell, Kiran Solanki, Y. Hammi

Research output: Contribution to journalArticle

42 Citations (Scopus)

Abstract

The fatigue behavior of resistance spot welding (RSW) in aluminum 6061-T6 alloy (AlMg1SiCu per International Standard Office nomenclature) was experimentally investigated. Three welding conditions, denoted as " nominal" , " low" and " high" , were studied to determine the microstructure of the weld nuggets. The process optimization included consideration of the forces, currents and times for main weld and post-heating. By successive iterations and " witness samples" collected, the optimum welding parameters were determined. Load control cyclic tests were then conducted on single weld lap-shear joint coupons to study the microstructure and fatigue life properties. These tests were used to characterize the fatigue behavior in spot welded specimens to elucidate the influence of the process parameters. This work revealed that the welding process parameters have a great influence in the microstructure and fatigue life of the 2. mm-thick aluminum sheet resistance spot welded joints. Different fatigue failure modes were observed at several load ranges and ratios for a constant frequency and three welding currents.

Original languageEnglish (US)
Pages (from-to)456-465
Number of pages10
JournalMaterials and Design
Volume45
DOIs
StatePublished - 2013

Fingerprint

Resistance welding
Spot welding
Aluminum alloys
Welding
Fatigue of materials
Welds
Microstructure
Aluminum sheet
Sheet resistance
Terminology
Aluminum
Failure modes
Heating

Keywords

  • Aluminum
  • Fatigue behavior
  • Microstructure
  • Process optimization
  • Resistance spot welding
  • Welding parameters

ASJC Scopus subject areas

  • Mechanical Engineering
  • Mechanics of Materials
  • Materials Science(all)

Cite this

Welding parameters influence on fatigue life and microstructure in resistance spot welding of 6061-T6 aluminum alloy. / Florea, R. S.; Bammann, D. J.; Yeldell, A.; Solanki, Kiran; Hammi, Y.

In: Materials and Design, Vol. 45, 2013, p. 456-465.

Research output: Contribution to journalArticle

@article{643426a89cba47dbaa3179d5e97b4d3b,
title = "Welding parameters influence on fatigue life and microstructure in resistance spot welding of 6061-T6 aluminum alloy",
abstract = "The fatigue behavior of resistance spot welding (RSW) in aluminum 6061-T6 alloy (AlMg1SiCu per International Standard Office nomenclature) was experimentally investigated. Three welding conditions, denoted as {"} nominal{"} , {"} low{"} and {"} high{"} , were studied to determine the microstructure of the weld nuggets. The process optimization included consideration of the forces, currents and times for main weld and post-heating. By successive iterations and {"} witness samples{"} collected, the optimum welding parameters were determined. Load control cyclic tests were then conducted on single weld lap-shear joint coupons to study the microstructure and fatigue life properties. These tests were used to characterize the fatigue behavior in spot welded specimens to elucidate the influence of the process parameters. This work revealed that the welding process parameters have a great influence in the microstructure and fatigue life of the 2. mm-thick aluminum sheet resistance spot welded joints. Different fatigue failure modes were observed at several load ranges and ratios for a constant frequency and three welding currents.",
keywords = "Aluminum, Fatigue behavior, Microstructure, Process optimization, Resistance spot welding, Welding parameters",
author = "Florea, {R. S.} and Bammann, {D. J.} and A. Yeldell and Kiran Solanki and Y. Hammi",
year = "2013",
doi = "10.1016/j.matdes.2012.08.053",
language = "English (US)",
volume = "45",
pages = "456--465",
journal = "Materials and Design",
issn = "0261-3069",
publisher = "Elsevier BV",

}

TY - JOUR

T1 - Welding parameters influence on fatigue life and microstructure in resistance spot welding of 6061-T6 aluminum alloy

AU - Florea, R. S.

AU - Bammann, D. J.

AU - Yeldell, A.

AU - Solanki, Kiran

AU - Hammi, Y.

PY - 2013

Y1 - 2013

N2 - The fatigue behavior of resistance spot welding (RSW) in aluminum 6061-T6 alloy (AlMg1SiCu per International Standard Office nomenclature) was experimentally investigated. Three welding conditions, denoted as " nominal" , " low" and " high" , were studied to determine the microstructure of the weld nuggets. The process optimization included consideration of the forces, currents and times for main weld and post-heating. By successive iterations and " witness samples" collected, the optimum welding parameters were determined. Load control cyclic tests were then conducted on single weld lap-shear joint coupons to study the microstructure and fatigue life properties. These tests were used to characterize the fatigue behavior in spot welded specimens to elucidate the influence of the process parameters. This work revealed that the welding process parameters have a great influence in the microstructure and fatigue life of the 2. mm-thick aluminum sheet resistance spot welded joints. Different fatigue failure modes were observed at several load ranges and ratios for a constant frequency and three welding currents.

AB - The fatigue behavior of resistance spot welding (RSW) in aluminum 6061-T6 alloy (AlMg1SiCu per International Standard Office nomenclature) was experimentally investigated. Three welding conditions, denoted as " nominal" , " low" and " high" , were studied to determine the microstructure of the weld nuggets. The process optimization included consideration of the forces, currents and times for main weld and post-heating. By successive iterations and " witness samples" collected, the optimum welding parameters were determined. Load control cyclic tests were then conducted on single weld lap-shear joint coupons to study the microstructure and fatigue life properties. These tests were used to characterize the fatigue behavior in spot welded specimens to elucidate the influence of the process parameters. This work revealed that the welding process parameters have a great influence in the microstructure and fatigue life of the 2. mm-thick aluminum sheet resistance spot welded joints. Different fatigue failure modes were observed at several load ranges and ratios for a constant frequency and three welding currents.

KW - Aluminum

KW - Fatigue behavior

KW - Microstructure

KW - Process optimization

KW - Resistance spot welding

KW - Welding parameters

UR - http://www.scopus.com/inward/record.url?scp=84867818347&partnerID=8YFLogxK

UR - http://www.scopus.com/inward/citedby.url?scp=84867818347&partnerID=8YFLogxK

U2 - 10.1016/j.matdes.2012.08.053

DO - 10.1016/j.matdes.2012.08.053

M3 - Article

AN - SCOPUS:84867818347

VL - 45

SP - 456

EP - 465

JO - Materials and Design

JF - Materials and Design

SN - 0261-3069

ER -