Multi-scale mechanical modeling of Al-steel resistance spot welds

Jian Chen; Zhili Feng; Hui Ping Wang; Blair E. Carlson; Tyson Brown; David Sigler

doi:10.1016/j.msea.2018.08.039

Multi-scale mechanical modeling of Al-steel resistance spot welds

Jian Chen, Zhili Feng, Hui Ping Wang, Blair E. Carlson, Tyson Brown, David Sigler

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Abstract

A multi-scale finite element modeling approach was developed to study the deformation and fracture behavior of Al-steel resistance spot welds. First, a micro-scale model was applied to simulate the mechanical responses of the intermetallic compound (IMC) layer having various morphologies and thicknesses under tensile and shear loading conditions. Second, the predicted tensile and shear strength of the IMC layer, that varied along the joint interface per the IMC layer morphology and thickness variation, was then introduced into 3D macro-scale models to predict the overall mechanical performance of weld coupons under coach peel, lap shear and cross-tension testing conditions. The numerical predictions agreed reasonably well with the experimental data.

Original language	English
Pages (from-to)	145-153
Number of pages	9
Journal	Materials Science and Engineering: A
Volume	735
DOIs	https://doi.org/10.1016/j.msea.2018.08.039
State	Published - Sep 26 2018

Funding

This manuscript has been co-authored by UT-Battelle, LLC under Contract No. DE-AC05-00OR22725 with the U.S. Department of Energy. The United States Government retains and the publisher, by accepting the article for publication, acknowledges that the United States Government retains a non-exclusive, paid-up, irrevocable, worldwide license to publish or reproduce the published form of this manuscript, or allow others to do so, for United States Government purposes. The Department of Energy will provide public access to these results of federally sponsored research in accordance with the DOE Public Access Plan ( http://energy.gov/downloads/doe-public-access-plan ).

Funders	Funder number
UT-Battelle, LLC

Keywords

Al-steel resistance spot welds
Deformation and fracture
Finite element modeling
Intermetallic compound

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10.1016/j.msea.2018.08.039

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title = "Multi-scale mechanical modeling of Al-steel resistance spot welds",

abstract = "A multi-scale finite element modeling approach was developed to study the deformation and fracture behavior of Al-steel resistance spot welds. First, a micro-scale model was applied to simulate the mechanical responses of the intermetallic compound (IMC) layer having various morphologies and thicknesses under tensile and shear loading conditions. Second, the predicted tensile and shear strength of the IMC layer, that varied along the joint interface per the IMC layer morphology and thickness variation, was then introduced into 3D macro-scale models to predict the overall mechanical performance of weld coupons under coach peel, lap shear and cross-tension testing conditions. The numerical predictions agreed reasonably well with the experimental data.",

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AU - Feng, Zhili

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AU - Carlson, Blair E.

AU - Brown, Tyson

AU - Sigler, David

PY - 2018/9/26

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AB - A multi-scale finite element modeling approach was developed to study the deformation and fracture behavior of Al-steel resistance spot welds. First, a micro-scale model was applied to simulate the mechanical responses of the intermetallic compound (IMC) layer having various morphologies and thicknesses under tensile and shear loading conditions. Second, the predicted tensile and shear strength of the IMC layer, that varied along the joint interface per the IMC layer morphology and thickness variation, was then introduced into 3D macro-scale models to predict the overall mechanical performance of weld coupons under coach peel, lap shear and cross-tension testing conditions. The numerical predictions agreed reasonably well with the experimental data.

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Multi-scale mechanical modeling of Al-steel resistance spot welds

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