Skip to main content
SpringerLink
Log in

Effects of various strength defects of spot weld on the connection strength under both static and cyclic loading conditions: empirical and numerical investigation

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

Abstract

During the spot welding process, it is always possible to be made defects, and the most important reasons for defects can be due to incorrect settings of current, force, and time. In other words, at different time intervals depending on the working conditions of the welding machine (i.e., both manual and robotic machines), such as the erosion of the electrode head, it is necessary to optimize the welding parameters and apply the essential changes in the next settings. The presence of various defects reduces the quality and strength of spot welds and eventually structures, which is one of the main concerns in automotive, aerospace, and marine industries. Therefore, in the present research, the authors have tried to investigate the effects of two important strength defects, including undersized and stick, on the spot-welded connection strength under static and cyclic loading. To this end, different samples of three-sheet spot-welded joint with defects of undersized and stick and free-defect were prepared based on the results of previous studies and using available relationships for the nugget diameter in terms of welding parameters, i.e., force, quadrilateral times (squeeze, up slope, welding time, and hold), and current of spot welding process. Next, metallographic, tensile, and axial fatigue tests were performed to obtain the nugget diameter, static strength of the connection, and fatigue behavior of the connection in different classifications of the samples, respectively. Furthermore, numerical analysis including the simulation of the welding process and the simulation of tensile and fatigue tests was performed in the finite element software. Numerical and experimental results have an acceptable correlation. Finally, both methods show that the nugget diameter is an influencing parameter on the tensile strength and fatigue life of spot welds, which reduces the fatigue life by 60% when the nugget diameter is reduced by 44%. Moreover, the stick defect also decreases the fatigue life of the spot-welded connection, while its effect is different depending on the geometry of welding core, including penetration height and nugget diameter.

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

Similar content being viewed by others

Data availability

All the data have been presented in the manuscript.

Code availability

Not applicable.

References

  1. Tsai CL, Papritan JC, Dickinson DW, Jammal O (1992) Modeling of resistance spot weld nugget growth. Weld J 71(2):47

    Google Scholar 

  2. Amiri N, Farrahi GH, Kashyzadeh KR, Chizari M (2020) Applications of ultrasonic testing and machine learning methods to predict the static & fatigue behavior of spot-welded joints. J Manuf Process 52:26–34. https://doi.org/10.1016/j.jmapro.2020.01.047

    Article  Google Scholar 

  3. Patil SA, Baratzadeh F, Lankarani H (2017) Modeling of the weld strength in spot weld using regression analysis of the stress parameters based on the simulation study. J Mater Sci 6:51–62. https://doi.org/10.5539/jmsr.v6n1p51

    Article  Google Scholar 

  4. Raut M, Achwal V (2014) Optimization of spot welding process parameters for maximum tensile strength. Int J Mech Eng Robot Res 3(4):507–517

    Google Scholar 

  5. Martín Ó, Pereda M, Santos JI, Galán JM (2014) Assessment of resistance spot welding quality based on ultrasonic testing and tree-based techniques. J Mater Process Technol 214(11):2478–2487. https://doi.org/10.1016/j.jmatprotec.2014.05.021

    Article  Google Scholar 

  6. Amiri N, Farrahi GH, Reza Kashyzadeh K, Ostad Rahimi M, Barforoushan S (2019) Reliability study of non-destructive inspections of resistance spot welds in the automotive industry. The 5th International and 16th National Conference on Manufacturing Engineering, Tehran, Iran. https://civilica.com/doc/998293. Accessed 01 Mar 2020

    Google Scholar 

  7. Farrahi GH, Ahmadi A, Kasyzadeh KR (2020) Simulation of vehicle body spot weld failures due to fatigue by considering road roughness and vehicle velocity. Simul Model Pract Theory 105:102168. https://doi.org/10.1016/j.simpat.2020.102168

    Article  Google Scholar 

  8. Reza Kashyzadeh K, Ghorbani S (2023) High-cycle fatigue behavior and chemical composition empirical relationship of low carbon three-sheet spot-welded joint: an application in automotive industry. Int J Fatigue 2(1):1–8

    Google Scholar 

  9. Patil DV, Sankpal GA (2014) A review on effect of spot weld parameters on spot weld strength. Int J Eng Res 3(1):1

    Google Scholar 

  10. Farrahi GH, Ahmadi A, Kashyzadeh KR, Azadi S, Jahani K (2020) A comparative study on the fatigue life of the vehicle body spot welds using different numerical techniques: inertia relief and Modal dynamic analyses. Frattura ed Integrità Strutturale 14(52):67–81. https://doi.org/10.3221/IGF-ESIS.52.06

    Article  Google Scholar 

  11. Ghafarallahi E, Farrahi GH, Amiri N (2021) Acoustic simulation of ultrasonic testing and neural network used for diameter prediction of three-sheet spot welded joints. J Manuf Process 64:1507–1516. https://doi.org/10.1016/j.jmapro.2021.03.012

    Article  Google Scholar 

  12. Ertas AH, Sonmez FO (2008) A parametric study on fatigue strength of spot-weld joints. Fatigue Fract Eng Mater Struct 31(9):766–776. https://doi.org/10.1111/j.1460-2695.2008.01263.x

    Article  Google Scholar 

  13. Farrahi GH, Chamani M, Kashyzadeh KR, Mostafazade A, Mahmoudi AH, Afshin H (2018) Failure analysis of bolt connections in fired heater of a petrochemical unit. Eng Fail Anal 92:327–342. https://doi.org/10.1016/j.engfailanal.2018.06.004

    Article  Google Scholar 

  14. Farrahi GH, Fallah A, Kashyzadeh KR (2023) Fracture toughness evaluation of 1.4841 bolt subjected to simultaneous effects of creep and hydrogen embrittlement phenomena using small punch test: a case study in a superheater of a petrochemical unit. Eng Fail Anal 144:106956. https://doi.org/10.1016/j.engfailanal.2022.106956

    Article  Google Scholar 

  15. Wang G, Barkey ME (2006) Investigating the spot weld fatigue crack growth process using X-ray imaging. Weld J 85(4):84–90

    Google Scholar 

  16. Reza Kashyzadeh K, Souri K, Gharehsheikh Bayat A, Safavi Jabalbarez R, Ahmad M (2022) Fatigue life analysis of automotive cast iron knuckle under constant and variable amplitude loading conditions. Applied Mech 3(2):517–532. https://doi.org/10.3390/applmech3020030

    Article  Google Scholar 

  17. Pook LP (1975) Fracture mechanics analysis of the fatigue behaviour of spot welds. Int J Fract 11:173–176. https://doi.org/10.1007/BF00034726

    Article  Google Scholar 

  18. Bae DH, Sohn IS, Hong JK (2003) Assessing the effects of residual stresses on the fatigue strength of spot welds. Weld J 82(1):18-S

    Google Scholar 

  19. Reza Kashyzadeh K, Farrahi G, Ahmadi A, Minaei M, Ostad Rahimi M, Barforoushan S (2023) Fatigue life analysis in the residual stress field due to resistance spot welding process considering different sheet thicknesses and dissimilar electrode geometries. Proc Inst Mech Eng L: J Mater: Des Appl 237(1):33–51. https://doi.org/10.1177/14644207221101069

    Article  Google Scholar 

  20. Pal TK, Bhowmick K (2012) Resistance spot welding characteristics and high cycle fatigue behavior of DP 780 steel sheet. J Mater Eng Perform 21:280–285. https://doi.org/10.1007/s11665-011-9850-2

    Article  Google Scholar 

  21. Xiao L, Liu L, Chen DL, Esmaeili S, Zhou Y (2011) Resistance spot weld fatigue behavior and dislocation substructures in two different heats of AZ31 magnesium alloy. Mater Sci Eng A 529:81–87. https://doi.org/10.1016/j.msea.2011.08.064

    Article  Google Scholar 

  22. Ordoñez JH, Ambriz RR, García 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. https://doi.org/10.1016/j.ijfatigue.2018.12.026

    Article  Google Scholar 

  23. Hassanifard S, Zehsaz M, Esmaeili F (2011) Spot weld arrangement effects on the fatigue behavior of multi-spot welded joints. J Mech Sci Technol 25:647–653. https://doi.org/10.1007/s12206-011-0112-x

    Article  Google Scholar 

  24. Esmaeili F, Rahmani A, Barzegar S, Afkar A (2015) Prediction of fatigue life for multi-spot welded joints with different arrangements using different multiaxial fatigue criteria. Mater Des 72:21–30. https://doi.org/10.1016/j.matdes.2015.02.008

    Article  Google Scholar 

  25. Liu W, Fan H, Guo X, Huang Z, Han X (2016) Mechanical properties of resistance spot welded components of high strength austenitic stainless steel. J Mater Sci Technol 32(6):561–565. https://doi.org/10.1016/j.jmst.2015.11.023

    Article  Google Scholar 

  26. Vural M, Akkuş A, Eryürek B (2006) Effect of welding nugget diameter on the fatigue strength of the resistance spot welded joints of different steel sheets. J Mater Process Technol 176(1-3):127–132. https://doi.org/10.1016/j.jmatprotec.2006.02.026

    Article  Google Scholar 

  27. Liu L, Xiao L, Chen DL, Feng JC, Kim S, Zhou Y (2013) Microstructure and fatigue properties of Mg-to-steel dissimilar resistance spot welds. Mater Des 45:336–342. https://doi.org/10.1016/j.matdes.2012.08.018

    Article  Google Scholar 

  28. Browne DJ, Chandler HW, Evans JT, Wen J (1995) Computer simulation of resistance spot welding in aluminum: part I. Weld J Res Suppl 74(10):339s

    Google Scholar 

  29. Kong X, Yang Q, Li B, Rothwell G, English R, Ren XJ (2008) Numerical study of strengths of spot-welded joints of steel. Mater Des 29(8):1554–1561. https://doi.org/10.1016/j.matdes.2007.12.001

    Article  Google Scholar 

  30. Junqueira DM, Silveira ME, Ancelotti AC (2018) Analysis of spot weld distribution in a weldment—numerical simulation and topology optimization. Int J Adv Manuf Technol 95:4071–4079. https://doi.org/10.1007/s00170-017-1555-8

    Article  Google Scholar 

  31. DiGiovanni 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. https://doi.org/10.1016/j.jmapro.2019.11.015

    Article  Google Scholar 

  32. Bhuvaneswaran S, Padmanaban R (2021) Prediction of spot weld fatigue life using finite element approach. Mater Today: Proc 46:9875–9881. https://doi.org/10.1016/j.matpr.2020.12.816

    Article  Google Scholar 

  33. Zhu T, Xiao SN, Yang GW, Miao BR (2010) Fatigue life prediction of spot-welded structure under different finite element models of spot-weld. In: Advanced Materials Research, vol 118. Trans Tech Publications Ltd., pp 191–195. https://doi.org/10.4028/www.scientific.net/AMR.118-120.191

    Chapter  Google Scholar 

  34. Nodeh IR, Serajzadeh S, Kokabi AH (2008) Simulation of welding residual stresses in resistance spot welding, FE modeling and X-ray verification. J Mater Process Technol 205(1-3):60–69. https://doi.org/10.1016/j.jmatprotec.2007.11.104

    Article  Google Scholar 

  35. Grujicic M, Ramaswami S, Snipes JS, Yavari R, Arakere A, Yen CF, Cheeseman BA (2013) Computational modeling of microstructural-evolution in AISI 1005 steel during gas metal arc butt welding. J Mater Eng Perform 22:1209–1222. https://doi.org/10.1007/s11665-012-0402-1

    Article  Google Scholar 

  36. Farrahi GH, Kashyzadeh KR, Minaei M, Sharifpour A, Riazi S (2020) Analysis of resistance spot welding process parameters effect on the weld quality of three-steel sheets used in automotive industry: experimental and finite element simulation. Int J Eng 33(1):148–157. https://doi.org/10.5829/ije.2020.33.01a.17

    Article  Google Scholar 

  37. Dong P, Hong JK, Cao Z (2001) A mesh-insensitive structural stress procedure for fatigue evaluation of welded structures. International Institute of Welding

    Google Scholar 

  38. Dong P (2005) A robust structural stress method for fatigue analysis of offshore/marine structures. J Offshore Mech Arct Eng 127(1):68–74. https://doi.org/10.1115/1.1854698

    Article  Google Scholar 

  39. Hong JK (2011) The development of a simplified spot weld model for Battelle structural stress calculation. SAE Int J Mater Manuf 4(1):602–612. https://doi.org/10.4271/2011-01-0479

    Article  Google Scholar 

  40. Dong P, Prager M, Osage D (2007) The design master SN curve in ASME Div 2 rewrite and its validations. Weld World 51:53–63. https://doi.org/10.1007/BF03266573

    Article  Google Scholar 

  41. Reza Kashyzadeh K, Farrahi GH, Minaei M, Masajedi R, Gholamnia M, Shademani M (2022) Numerical study of shunting effect in three-steel sheets resistance spot welding. Int J Eng 35(2):406–416. https://doi.org/10.5829/ije.2022.35.02b.17

    Article  Google Scholar 

Download references

Acknowledgements

The authors would like to thank Sharif University of Technology for their support in sample preparation and conducting various tests. This paper has been supported by the RUDN University Strategic Academic Leadership Program (recipient: Prof. Dr. K. Reza Kashyzadeh).

Author information

Authors and Affiliations

  1. Materials Life Estimation and Improvement Laboratory, Sharif University of Technology, Tehran, 11365, Iran

    Mohammad Amin Ganjabi & GholamHossein Farrahi

  2. School of Mechanical Engineering, Sharif University of Technology, Tehran, 11365, Iran

    GholamHossein Farrahi

  3. Department of Transport, Academy of Engineering, RUDN University, 6 Miklukho-Maklaya St, Moscow, 117198, Russian Federation

    Kazem Reza Kashyzadeh

  4. Paul M. Rady Department of Mechanical Engineering, University of Colorado, Boulder, CO, 80309, USA

    Nima Amiri

Authors
  1. Mohammad Amin Ganjabi
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. GholamHossein Farrahi
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Kazem Reza Kashyzadeh
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Nima Amiri
    View author publications

    You can also search for this author in PubMed Google Scholar

Contributions

Mohammad Amin Ganjabi: investigation, data analysis, software, writing—original draft preparation. GholamHossein Farrahi: conceptualization, supervisor, writing—reviewing and editing. Kazem Reza Kashyzadeh: conceptualization, supervisor, data analysis, software, validation, experiment, writing—reviewing and editing. Nima Amiri: investigation, writing—original draft preparation.

Corresponding author

Correspondence to Kazem Reza Kashyzadeh.

Ethics declarations

Ethics approval

The authors state that the present work is in compliance with the ethical standards.

Consent to participate

The authors declare that they all consent to participate in this research.

Consent for publication

The authors declare that they all consent to publish the manuscript.

Competing interests

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

Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Ganjabi, M.A., Farrahi, G., Reza Kashyzadeh, K. et al. Effects of various strength defects of spot weld on the connection strength under both static and cyclic loading conditions: empirical and numerical investigation. Int J Adv Manuf Technol 127, 5665–5678 (2023). https://doi.org/10.1007/s00170-023-11923-y

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-023-11923-y

Keywords

Search

Navigation