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Determination of resistance spot weld failure path in ultra-high-strength press-hardened steel by control of fusion boundary transient softening

  • Metals & corrosion
  • Published:
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Abstract

The use of coated press-hardened steels (PHS) in body-in-white (BiW) components provides significant potential for weight reduction, but leads to decrease in joinability, thus creating challenge to produce welds meeting commercial quality requirements. Welding with longer welding times can improve joinability, but causes softening at the fusion boundary of spot welds due to local decarburization, referred to as a “halo” at the fusion boundary. In the present work, RSW with and without a softened region at the fusion boundary were fabricated. The geometry and hardness of the halo were obtained from high-resolution hardness mappings and transferred to an FE model, which was used to predict mechanical performance and fracture mode of spot welds in lap-shear and cross-tension tests. The developed FE model was verified experimentally and allowed for an accurate prediction of failure modes while demonstrating that the presence of the halo ring affects the location of failure as well as the load–displacement response of spot welds.

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Acknowledgements

The authors thank Honda R&D Americas Inc., Promatek Research Centre, ArcelorMittal, the Natural Sciences and Engineering Research Council (NSERC) of Canada and the Ontario Advanced Manufacturing Consortium for their funding of this work. Equal thanks go to AiF for funding the IGF-Project IGF-Nr.:18.939B (DVS-Nr.: 04.060) of the Research Association on Welding and Allied Processes of the DVS, which was part of the program to support cooperative industrial research (Industrielle Gemeinschaftsforschung (IGF)) by the Federal Ministry for Economic Affairs and Energy, following a decision of the German Bundestag. We also thank all companies, colleagues, and students who contributed their support, knowledge, and effort to the project.

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Authors and Affiliations

  1. Institute of Materials and Joining, Otto von Guericke University, Magdeburg, Germany

    Oleksii Sherepenko, Anastasiia Zvorykina & Sven Jüttner

  2. Department of Mechanical and Mechatronics Engineering, University of Waterloo, Waterloo, ON, Canada

    Oleksii Sherepenko, Alireza Mohamadizadeh, Michael Worswick & Elliot Biro

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  1. Oleksii Sherepenko
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  2. Alireza Mohamadizadeh
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  3. Anastasiia Zvorykina
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  4. Michael Worswick
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  6. Sven Jüttner
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Correspondence to Oleksii Sherepenko.

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Sherepenko, O., Mohamadizadeh, A., Zvorykina, A. et al. Determination of resistance spot weld failure path in ultra-high-strength press-hardened steel by control of fusion boundary transient softening. J Mater Sci 56, 14287–14297 (2021). https://doi.org/10.1007/s10853-021-06165-w

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