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Effects of double pulse welding on microstructure, texture, and fatigue behavior of DP590 steel resistance spot weld

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Abstract

In the present study, dual-phase (DP590) steel sheets were joined using single-pulse and double-pulse resistance spot welding in lap joint configuration. Effects of the welding method on microstructure, texture, tensile shear properties (load carrying and energy absorption capacity), and fatigue strength of welded joints were investigated. Tensile shear test results showed that double-pulse weld exhibits an average of 15.6% and 83.1% higher peak load and failure energy, respectively than single-pulse weld. Fatigue test results showed that double-pulse welds withstand 10.8%, 22.7%, 1.8%, 158.7%, and 20.2% higher number of cycles than single-pulse welds at an applied load of 2.3, 2.76, 3.45, 4.6, and 8.1 kN, respectively. The better mechanical performance of the double pulse spot welds is attributed to the large nugget size resulting in higher bonding area, the tough microstructure of the nugget consisting of tempered martensite structure, acicular ferrite, and Widmanstätten ferrite, and the formation of randomly orientated grains with a high fraction of high angle boundaries in the fusion zone, which resulted in improved resistance to crack propagation during mechanical loading.

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Data availability

The data that support the findings of this study are available from the corresponding author upon reasonable request.

Code availability

Not applicable.

Abbreviations

SPW:

Single pulse welding

DPW:

Double pulse welding

DP:

Dual phase

FZ:

Fusion zone

HAZ:

Heat affected zone

CGHAZ:

Coarse grain heat affected zone

FGHAZ:

Fine grain heat affected zone

SCHAZ:

Subcritical heat affected zone

RSW:

Resistance spot welding

PAG:

Prior austenite grain

LAGBs:

Low angle grain boundaries

HAGBs:

High angle grain boundaries

PF:

Pullout failure

IF:

Interfacial failure

FL:

Failure location

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Acknowledgements

The authors would like to acknowledge the Bloxwich Sdn Bhd Malaysia for providing a resistance spot welding facility. The authors would also like to acknowledge High-Tech Instrument Sdn Bhd Malaysia for providing a Backscattered Electron Diffraction facility and MIMOS Sdn Bhd Malaysia for providing a nanoindentation facility. The authors are also thankful to Mr. Nasrizal for his assistance in conducting fatigue tests at UNiKL Malaysia.

Funding

This work was supported by the University Teknologi PETRONAS (UTP) Malaysia grant [015LCO-129]. Mokhtar Awang received the grant from UTP.

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Authors and Affiliations

  1. Department of Mechanical Engineering, Universiti Teknologi PETRONAS, 32610, Seri Iskandar, Perak Darul Ridzuan, Malaysia

    Imtiaz Ali Soomro, Srinivasa Rao Pedapati, Mokhtar Awang & Mohammad Azad Alam

  2. Department of Metallurgy and Materials Engineering, Mehran University of Engineering and Technology, Jamshoro, 76062, Sindh, Pakistan

    Imtiaz Ali Soomro

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  1. Imtiaz Ali Soomro
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Correspondence to Imtiaz Ali Soomro.

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Soomro, I.A., Pedapati, S.R., Awang, M. et al. Effects of double pulse welding on microstructure, texture, and fatigue behavior of DP590 steel resistance spot weld. Int J Adv Manuf Technol 125, 1271–1287 (2023). https://doi.org/10.1007/s00170-022-10704-3

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