Skip to main content
SpringerLink
Log in

Experimental study on fatigue performance of resistance spot-welded sheet metals

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

Resistance spot welding is used as a reliable joining process in many engineering applications because of its effectiveness, automation capability, and low cost. The spot-welded sheet metals, on the other hand, are prone to mechanical fatigue failure, especially under cyclic loadings. Therefore, understanding and elucidating the fatigue phenomenon of the spot-welded joints are crucial in terms of estimating and preventing undesired failure conditions. In the design phase, there exist a considerable amount of challenges to overcome; one of the most important challenges is to select optimum working conditions. Hence, in this study, the fatigue phenomenon of the spot-welded sheet metals is investigated experimentally, by taking electrode force into consideration. For this purpose, spot-welded modified tensile shear (MTS) test specimens were utilized. A series of fatigue life tests were conducted to examine the influence of electrode force on fatigue life. The results obtained through an optical microscope were presented and interpreted. Experimental data showed that the number of cycles to failure changes depending on the spot-generating schemes in terms of electrode force and welding schedules. Through the investigation of an optical micrograph of partially failed spot-welded MTS specimens for different groups of spot welds created under different electrode force effects, it is seen that the fatigue failure is dominated by the through-thickness cracking. Comparing both crack formation and also fatigue lives of different groups of spot-welded MTS specimens, it is shown that the electrode force and accordingly thermal interaction play an important role in the fatigue strength of the spot-welded specimens.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15
Fig. 16

Similar content being viewed by others

References

  1. Krause AR, Thornton PH, Davies RG (1996) The aluminum spot weld. Weld J:101 s–108 s

  2. Pollard B (1982) Fatigue strength of spot welds in titanium-bearing HSLA steels. Proceedings of the SAE International Congress and Exposition, Detroit

    Google Scholar 

  3. Matsika E, O’Neill C, Grasso M, De Lorio A (2018) Selection and ranking of the main beam geometry of a freight wagon for light weighting. P I Mech Eng F-Rai 232(2):495–513

    Google Scholar 

  4. Ertas AH, Sonmez FO (2008) A parametric study on fatigue strength of spot-weld joints. Fatigue Fract Eng M 31(9):766–776

    Google Scholar 

  5. Ertas AH, Vardar O, Sonmez FO, Solim Z (2009) Measurement and assessment of fatigue life of spot-weld joints. J Eng Mater-T ASME 131(1):011011

    Article  Google Scholar 

  6. Rathbun RW, Matlock DK, Speer JG (2003) Fatigue behavior of spot-welded high-strength sheet steels. Weld J:207 s–218 s

  7. Chao YJ (2003) Failure mode of spot welds: interfacial versus pullout. Sci Technol Weld Join 8(2):133–137

    Google Scholar 

  8. Chao YJ (2003) Ultimate strength and failure mechanism of resistance spot weld subjected to tensile, shear, or combined tensile/shear loads. J Eng Mater T ASME 125:125–132

    Article  Google Scholar 

  9. Ertas AH, Yilmaz Y, Baykara C (2008) An investigation of the effect of the gap values between the overlap portions of the spot-welded pieces on fatigue life. P I Mech Eng C-Mec 222(6):881–890

    Article  Google Scholar 

  10. Ertas AH (2015) Design optimization of spot welded structures to attain maximum strength. Steel Compos Struct 19(4):995–1009

    Article  Google Scholar 

  11. Ertas AH, Sonmez FO (2011) Design optimization of spot-welded plates for maximum fatigue life. Finite Elem Anal Des 47(4):413–423

    Article  Google Scholar 

  12. Linder J, Melander A (1998) Fatigue strength of spot welded stainless sheet steels exposed to 3% NaCl solution. Int J Fatigue 20(5):383–388

    Article  Google Scholar 

  13. Henrysson HF (2000) Fatigue life prediction of spot welds using coarse FE meshes. Fatigue Fract Eng M 23(9):737–746

    Article  Google Scholar 

  14. Di Fant-Jaeckels H, Galtier A (2000) Fatigue lifetime prediction model for spot welded structures. La Revue de Metallurgie-CIT 1:83–95

    Article  Google Scholar 

  15. Ordonez CH, Ambriz RR, Garcia C, Plascencia G, Jaramillo D (2019) Overloading effect on the fatigue strength in resistance spot welding joints of a DP980 steel. Int J Fatigue 121:163–171

    Article  Google Scholar 

  16. Ao S, Shan H, Cui X, Luo Z, Chao YJ, Ma M (2016) Effect of specimen width on the failure behavior in resistance spot weld tensile shear testing. Weld World 60:1095–1107

    Article  Google Scholar 

  17. Nikolic RR, Djokovic JM, Hadzima B, Ulewicz R (2020) Spot-weld service life estimate based on application of the interfacial crack concept. Materials 13:2976

    Article  Google Scholar 

  18. Akbulut M (In press) Parametric investigation into fatigue life behavior of spot welded tensile shear test samples. P I Mech Eng C-Mec: https://doi.org/10.1177/0954406220966352

  19. Cho H, Nam S, Hwang I, Oh JH, Kang M, Kim YM (2019) Fatigue behaviors of resistance spot welds for 980 MPa grade TRIP steel. Metals 9:1086

    Article  Google Scholar 

  20. Florea RS, Bammann DJ, Yeldell A, Solank KN, Hammi Y (2013) Welding parameters influence on fatigue life and microstructure in resistance spot welding of 6061-T6 aluminum alloy. Mater Des 45:456–465

    Article  Google Scholar 

  21. Di Giovanni C, He L, Pistek U, Goodwin F, Biro E, Zhou NY (2020) Role of spot weld electrode geometry on liquid metal embrittlement crack development. J Manuf Process 49:1–9

    Article  Google Scholar 

  22. Pan N (2020) Fatigue life study of spot welds. PhD. Thesis: Stanford University.

  23. Zhao DW, Wang YX, Zhang L, Zhang P (2013) Effects of electrode force on microstructure and mechanical behavior of the resistance spot welded DP600 joint. Mater Des 50:72–77

    Article  Google Scholar 

  24. Jo H, Kim D, Kang M, Park J, Kim YM (2019) Effects of surface roughness and force of electrode on resistance spot weldability of aluminum 6061 alloy. Appl Sci 9(19):3958

    Article  Google Scholar 

  25. Zhang Y, Taylor D (2000) Sheet thickness effect of spot welds based on crack propagation. Eng Fract Mech 67:55–63

    Article  Google Scholar 

  26. Cooper JF, Smith RA (1985) The measurement of fatigue cracks at spot welds. Int J Fatigue 7(3):137–140

    Article  Google Scholar 

  27. Damico DJ, Wilkinson TL, Niks LF Predicting performance of adhesively bonded joints based on acousto-ultrasonic evaluation. American Society for Testing and Materials, Philadelphia

  28. Gero BM (1997) Acousto-ultrasonic evaluation of cyclic fatigue of spot welded structures. Ms. Thesis: Virginia Polytechnic Institute and State University

  29. Swellaw MH, Kurath P, Lawrence FV (1986) Electric-potential-drop studies of fatigue crack development in tensile-shear spot welds. Advances in Fatigue Lifetime Predictive Techniques, ASTM STP

  30. Sperle JO (1983) Strength of spot welds in high strength steel sheets. Met Constr-Brit Weld 15(4):200–203

    Google Scholar 

  31. Overbeeke JL, Draisma J (1974) Fatigue characteristics of heavy-duty spot welded lap joints. Met Constr-Brit Weld 6(7):213–219

    Google Scholar 

  32. Zhou M, Hu SJ, Zhang H (1999) Critical specimen sizes for tensile-shear testing of steel sheets. Weld J:305 s–313 s

  33. Ong JH (1993) An improved technique for the prediction of axial fatigue life from tensile data. Int J Fatigue 15(3):213–219

    Article  Google Scholar 

  34. Ertas AH (2004) Fatigue behavior of spot welds. M.Sc. Thesis: Bogazici University

  35. Stephens RI, Fatemi A, Stephens RR, Fuchs HO (2001) Metal fatigue in engineering. A Wiley-Interscience Publication.

  36. Davidson JA (1982) A review of the fatigue properties of spot-welded sheet steels. Proceedings of the SAE International Congress and Exposition, Detroit

    Google Scholar 

  37. Gean A, Westgate A, Kucza JC, Ehrstrom JC (1999) Static and fatigue behavior of spot-welded 5182-O Aluminum alloy sheet. Weld J:90s–96s

  38. Kan YR (1976) Fatigue resistance of spot welds - an analytical study. Met Eng Quart 16:26–36

    Google Scholar 

  39. Newman JA, Dowling NE (1998) A crack growth approach to life prediction on spot-welded lap joints. Fatigue Fract Eng M 21:1123–1132

    Article  Google Scholar 

  40. Shigley JE (1963) Mechanical engineering design.

  41. Schijve J (2001) Fatigue of structures and materials.

  42. Davidson JA, Imhof EJ (1983) A fracture-mechanics and system-stiffness approach to fatigue performance of spot-welded sheet steels. SAE Paper 830034 Soc. Auto. Engrs., Warrendale, PA

  43. Overbeeke JL, Draisma J (1978) Influence of stress relieving on fatigue of heavy duty spot welded lap joints. Met Constr-Brit Weld 10(9):433–434

    Google Scholar 

  44. Lin PC, Su ZM, He RY, Lin ZL (2012) Failure modes and fatigue life estimations of spot friction welds in cross-tension specimens of aluminum 6061-T6 sheets. Int J Fatigue 38:25–35

    Article  Google Scholar 

  45. Khanna SK, Long X (2008) Residual stresses in resistance spot welded steel joints. Sci Technol Weld Join 13(3):278–288

    Article  Google Scholar 

  46. Wang YR, Mo ZH, Feng JC, Zhang ZD (2007) Effect of welding time on microstructure and tensile shear load in resistance spot welded joints of AZ31Mg Alloy. Sci Technol Weld Join 12(8):671–676

    Article  Google Scholar 

  47. Böhne C, Meschut G, Biegler M, Frei J, Rethmeier M (2020) Prevention of liquid metal embrittlement cracks in resistance spot welds by adaption of electrode geometry. Sci Technol Weld Join 25(4):303–310

    Article  Google Scholar 

  48. Wakabayashi C, Furusako S, Miyazaki Y (2015) Strengthening spot weld joint by auto tempering acceleration at heat affected zone. Sci Technol Weld Join 20(6):468–472

    Article  Google Scholar 

  49. Hassanifard S, Bonab MAM, Jabbari G (2013) Investigation of fatigue crack propagation in spot-welded joints based on fracture mechanics approach. J Mater Eng Perform 22:245–250

    Article  Google Scholar 

  50. Xu J, Zhang YS, Xinmin L, Chen GL (2008) Experimental investigation of fatigue performance of spot welded dual phase sheet steels. Sci Technol Weld Join 13(8):726–731

    Article  Google Scholar 

Download references

Acknowledgements

This paper is based on the work supported by Mercedes-Benz Turk A.S. and Bogazici University. The authors would like to thank their colleague Dr. Mehmet Ipekoglu (from Turkisch-Deutsche Universitat) who provided insight and useful suggestions that greatly helped, and the research group of Mercedes-Benz Turk A.S., especially to Ismail Sarioglu, for their help and support during the preparation and testing of the specimens. The authors are also thankful for the constructive comments and suggestions of the anonymous reviewers that help the authors a lot to improve the manuscript quality. Last but not least, the authors are also grateful for using the facilities of Bogazici University.

Funding

This research did not receive any specific grant from funding agencies in the public, commercial, or not-for-profit sectors.

Author information

Authors and Affiliations

  1. Department of Mechanical Engineering, Bursa Technical University, 16330, Bursa, Turkey

    Ahmet H. Ertas

  2. Marmara Research Center, TUBITAK, 41470, Kocaeli, Turkey

    Mustafa Akbulut

Authors
  1. Ahmet H. Ertas
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Mustafa Akbulut
    View author publications

    You can also search for this author in PubMed Google Scholar

Contributions

The first (corresponding) author (Dr. Ahmet H. Ertas) carried out the experiments and also processed the experimental data. All the authors (Dr. Ahmet H. Ertas and Dr. Mustafa Akbulut) wrote the manuscript discussing all obtained data and literature. All authors provided critical feedback and helped shape the research and manuscript. All authors discussed the results and contributed to the final manuscript.

Corresponding author

Correspondence to Ahmet H. Ertas.

Ethics declarations

Ethics approval

Not applicable

Consent to participate

Not applicable

Consent for publication

The authors (copyright owner) warrant that they have the full power and authority to enter into this Agreement and to grant the rights granted in this Agreement. The authors hereby grant to the Journal a worldwide, irrevocable, non-exclusive, royalty-free license to publish or distribute the Work, to enter into arrangements with others to publish or distribute the Work, and to archive the Work. The authors agree that further publication of the Work, with the same or substantially the same content as appears in the Journal, will include an acknowledgment of prior publication in the Journal. It is affirmed that the authors are the sole authors of the Work titled as below, that neither this Work nor portions thereof have been published elsewhere and that this Work will not be submitted elsewhere.

Conflict of interest

The authors declare no competing interests.

Additional information

Publisher’s note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Ertas, A.H., Akbulut, M. Experimental study on fatigue performance of resistance spot-welded sheet metals. Int J Adv Manuf Technol 114, 1205–1218 (2021). https://doi.org/10.1007/s00170-021-06822-z

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-021-06822-z

Keywords

Search

Navigation