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Insights on Microstructure and Failure Characteristics of Resistance Spot Welds of Galvannealed Dual Phase Steel

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Abstract

This work examines the effect of spot-welding current on the load-bearing capacity and the fracture mechanism of galvannealed dual-phase steel (DP600) joints. A greater than three-fold increase in the load-bearing capacity of the joint was achieved by increasing the welding current from 6 to 9 kA. Quantitative fractography showed a transition from predominantly transgranular cleavage fracture at 6 kA current with only ~7 dimples to ~17% ductile dimples at 7 kA current and eventually 100% ductile dimples for 9 kA current. Detailed microstructure-hardness relationship across the different welding zones is presented using scanning electron microscopy and electron backscattered diffraction techniques. At the optimized welding parameter, load-controlled fatigue tests revealed a decrease in the number of cycles to failure with increasing load amplitude, and endurance was achieved for 10% of the maximum tensile-shear load-bearing capacity. Investigation of failed specimens revealed that while under tensile loading conditions, crack initiated from the base metal, fatigue crack initiated from the heat-affected zone. Also, the possibility of different categories of liquid metal embrittlement cracks are discussed.

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  1. R&D and Scientific Services, Tata Steel Limited, Jamshedpur, 831007, India

    Kaushal Kishore & Goutam Mukhopadhyay

  2. National Institute of Technology, Jamshedpur, 831014, India

    Pankaj Kumar

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Kishore, K., Kumar, P. & Mukhopadhyay, G. Insights on Microstructure and Failure Characteristics of Resistance Spot Welds of Galvannealed Dual Phase Steel. J. of Materi Eng and Perform 31, 10118–10136 (2022). https://doi.org/10.1007/s11665-022-07060-4

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